Technology disclosed herein relates to a member, a member manufacturing method, an electronic device, and an electronic device manufacturing method.
Fiber reinforced plastic is sometimes employed in casing for electronic devices. When the fiber reinforced plastic used is impermeable to radio-waves, such as carbon fiber reinforced plastic, it is possible that antenna sensitivity could drop in electronic devices with a built-in antenna. In order to secure antenna sensitivity, technology has been proposed in which a non-electrically conductive resin region, such as one of glass fiber reinforced plastic, is provided at a portion of the case corresponding to the antenna (see, for example, Patent Document 1).
Japanese Laid-Open Patent Application No. 2009-169506
Japanese Laid-Open Patent Application No. 2001-344580
Japanese Laid-Open Patent Application No. H11-45318
Japanese Laid-Open Patent Application No. 2009-23163
According to an aspect of the embodiments, a member includes a fiber part, which is a knitted article, and a wiring intertwined into the fiber part.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention.
First, explanation follows regarding a first exemplary embodiment of technology disclosed herein.
An electronic device 10 according to the first exemplary embodiment, illustrated in
As illustrated in
The main body 26 of the lower cover 20 is formed from a fiber reinforced plastic.
As illustrated in the cross-section (on the right) of
The electrically conductive wire 30 including the antenna 22 and the like is a separate member to a thread material 29 forming the fiber part 28, and more specifically, is intertwined into the fiber part 28 during a knitting process of the fiber part 28 (in the same fiber part 28 knitting process), at the same time as the fiber part 28 is formed. The electrically conductive wire 30 is, for example, formed thicker than the thread material employed in the fiber part 28, and is incorporated within gaps in the pattern of the fiber part 28.
Next, explanation follows regarding a manufacturing method (assembly method) of the electronic device 10 according to the first exemplary embodiment.
First, as illustrated in
The shape, size, and position of the antenna 22 and the lead-in wire 24 (see
In process A, as illustrated in
Next, in process C, as illustrated in
In process D, as illustrated in
In the lower cover 20 formed from the prepreg 38 in this manner, the electrically conductive wire 30 including the antenna 22, and the fiber part 28, are fully integrated together with the resin 36 that serves as a resin matrix. Note that the electrically conductive wire 30 may employ a covered wire, and the covered wire may employ a thermoplastic resin as the covering material. The covering material may then be softened or melted so as to be integrated together with the resin 36 during press molding.
Next, the lower cover 20 is, for example, injection molded (insert molded) after the above press molding. Various structural components are integrated into the lower cover 20 by this injection molding. Moreover, the upper cover 18 illustrated in
Components such as a display device, switches, and the like are then attached to the upper cover 18 and the lower cover 20, and the unit 14 is attached to the lower cover 20. The upper cover 18 is then attached to the lower cover 20 and the unit 14 is housed inside the case 12, thus completing the electronic device 10.
Next, explanation follows regarding operation and advantageous effects of the first exemplary embodiment.
As described in detail above, in the first exemplary embodiment, the antenna 22 is intertwined into the fiber part 28 as illustrated in
Moreover, since the lower cover 20 can be integrally formed, the number of components can be reduced in comparison to when, for example, the lower cover 20 is formed from plural members, thereby enabling a reduction in costs.
Moreover, the antenna 22 is intertwined into the fiber part 28 at the same time as the fiber part 28 is formed during the knitting process of the fiber part 28 (in the same fiber part 28 knitting process), thereby enabling the number of manufacturing processes to be reduced. This also enables a reduction in costs.
The structure in which the electrically conductive wire 30 including the antenna 22 and the like is intertwined into the fiber part 28 enables the antenna 22 to be formed on the outer side of the fiber part 28, namely, on the outer face side of the lower cover 20. This thereby enables good sensitivity of the antenna 22 to be achieved.
The structure in which the electrically conductive wire 30 including the antenna 22 and the like is intertwined into the fiber part 28 enables the electrically conductive wire 30 to run from the inner side to the outer side of the lower cover 20. This thereby renders a separate process to form the antenna 22 separately to the lead-in wire 24 unnecessary, enabling a reduction in costs.
As illustrated in
Moreover, as illustrated in
Moreover, the degrees of freedom in the layout of the antenna 22 can be improved since the electrically conductive wire 30 can be intertwined into the fiber part 28 at a freely selected location.
Moreover, as illustrated in
Next, explanation follows regarding modified examples of the first exemplary embodiment.
In the first exemplary embodiment, the lower cover 20 may, for example, be applied to other electronic devices, such as notebook computers, as well as mobile devices such as smartphones and tablets.
Moreover, the structure including the fiber part 28 and the antenna 22 in the lower cover 20 described above may also be applied to the upper cover 18 illustrated in
The lower cover 20 includes the antenna 22 as an example of “wiring”. However, wiring with a function other than that of the antenna 22 may be interwoven into the fiber part 28.
The fiber part 28 is impregnated with the resin 36 that serves as a resin matrix.
However, as the resin matrix, instead of the resin 36, the fiber part 28 may employ a pre-coated resin, or the fiber part 28 may employ resin fibers interwoven into the fiber part 28 in advance.
Next, explanation follows regarding a second exemplary embodiment of technology disclosed herein.
In the second exemplary embodiment, the structure of the lower cover 20 is modified from that of the first exemplary embodiment in the following manner. Namely, as illustrated in
As illustrated in
Next, explanation follows regarding a manufacturing method of the lower cover 20 according to the second exemplary embodiment.
First, as illustrated in
Then, as illustrated by process A in
Next, as illustrated by process C in
In the lower cover 20 formed from the prepreg 38 in this manner, the antenna 22, the lead-in wire 24, and the fiber part 28 are fully integrated together with the resin 36 that serves as a resin matrix. The lead-in wire 24 is connected to the antenna 22 by press molding in the superimposed state of the first layer 52 and the second layer 54, such that the antenna 22 and the lead-in wire 24 form the electrically conductive wire 30 running from the inner side to the outer side of the lower cover 20.
In the second exemplary embodiment, the first layer 52 intertwined with the antenna 22, and the second layer 54 intertwined with the lead-in wire 24, are superimposed and molded together, thereby enabling easy forming of the electrically conductive wire 30 running from the inner side to the outer side of the lower cover 20.
Note that in the second exemplary embodiment, bare wires may be employed for the antenna 22 and the lead-in wire 24. The respective connection portions of the antenna 22 and the lead-in wire 24 may then be connected by being integrated together in the press molding.
In the second exemplary embodiment, covered wire may be employed for the electrically conductive wire 30, and an electrically conductive resin may be employed as the covering material of the covered wire. The respective connection portions of the antenna 22 and the lead-in wire 24 may then be integrated together by softening or melting the covering material covering the connection portions by the press molding. Moreover, in such cases, copper wire coated with an electrically conductive paste as an electrically conductive adhesive may, for example, be employed as the electrically conductive wire 30.
Next, explanation follows regarding a third exemplary embodiment of technology disclosed herein.
In the third exemplary embodiment, the structure of the antenna 22 is modified from that of the first exemplary embodiment described above in the following manner. Namely, as illustrated in
The antenna 22 is interwoven into the fiber part 28 by substituting the thread material used to form the fiber part 28 with the electrically conductive wire 60 during the knitting process of the fiber part 28 (in the same process as the fiber part 28 knitting process). Since the antenna 22 is formed by substituting the thread material used to form the fiber part 28 with the electrically conductive wire 60, the antenna 22 forms a section of the pattern of the fiber part 28.
In the third exemplary embodiment, the antenna 22 is also formed integrally to the lower cover 20 when the antenna 22 is interwoven into the fiber part 28 by substituting the thread material used to form the fiber part 28 with the electrically conductive wire 60. The strength of the lower cover 20 can accordingly be secured since the lower cover 20 can be integrally formed without forming connection portions of plural members in the lower cover 20.
Moreover, since the antenna 22 is interwoven into the fiber part 28 by substituting the thread material used to form the fiber part 28 with the electrically conductive wire 60 in the knitting process of the fiber part 28, the number of manufacturing processes can be reduced, thereby enabling a reduction in costs.
Note that the thin electrically conductive wire 60 may be employed as-is in the antenna 22, as illustrated in
Namely, in the example illustrated in
In this manner, the adjacent loops 64 of the electrically conductive wire 60 are connected together by press molding, enabling the breadth of the antenna 22 to be increased in comparison to when the thin electrically conductive wire 60 is used as-is in the antenna 22, as illustrated in
Note that in the third exemplary embodiment, the electrically conductive wire 60 may be either bare wire or covered wire. Moreover, in cases in which covered wire is employed for the electrically conductive wire 60, an electrically conductive resin may be employed as the covering material of the covered wire.
The adjacent loops 64 of the electrically conductive wire 60 may then be connected by integrating together by softening or melting the covering material covering the loops 64 in press molding. Moreover, in such cases, copper wire coated with an electrically conductive paste as an electrically conductive adhesive may, for example, be employed as the electrically conductive wire 60.
Moreover, in the third exemplary embodiment, the lower cover 20 includes the antenna 22 as an example of “wiring”. However, wiring with a function other than that of the antenna 22 may be interwoven into the fiber part 28.
Explanation follows regarding a fourth exemplary embodiment of technology disclosed herein.
An electronic device 70 according to the fourth exemplary embodiment illustrated in
The wearable member 80 includes a fiber part 88, which is a knitted article. The fiber part 88 includes a general region 90 and a high strength region 92 (see also
The high strength region 92 is formed by changing the thread material used for the general region 90 adjacent to the high strength region 92 to a thread material with higher strength than the thread material of the general region 90. Resin-coated carbon fiber, for example, is preferably used as the thread material of the high strength region 92. Moreover, a thermoplastic resin or a thermosetting resin is used for the resin coating.
An antenna 22 is interwoven into the fiber part 88. The antenna 22 is configured as a separate member to the thread material forming the fiber part 88, similarly to in the first exemplary embodiment described above (see
Next, explanation follows regarding operation and advantageous effects of the fourth exemplary embodiment.
According to the fourth exemplary embodiment, the antenna 22 is interwoven into the fiber part 88 formed by knitting the thread material, and is either incorporated within gaps in the pattern of the fiber part 88, or forms a section of the pattern of the fiber part 88. Unevenness in volume of the fiber part 88, and thereby the occurrence of flaws such as distortion or irregularity in the fiber part 88, can accordingly be suppressed.
The antenna 22 is interwoven into the fiber part 88 at the same time as the fiber part 88 is formed during the knitting process of the fiber part 88 (in the same fiber part 88 knitting process). This thereby enables a reduction in the number of manufacturing processes. Accordingly, a reduction in costs can be achieved.
Moreover, the degrees of freedom in the layout of the antenna 22 can be improved since the antenna 22 can be interwoven into the fiber part 88 at a freely selected location.
Note that in the fourth exemplary embodiment, as illustrated in
Forming the support portion 94 to a section of the fiber part 88 in this manner enables components such as the unit 84 (see
Moreover, together with a section of the fiber part 88, the antenna 22 is integrated together with the support portion 94 that serves as a resin matrix, thereby enabling the antenna 22 to be protected.
Moreover, in the fourth exemplary embodiment, the wearable member 80 may be configured in a wearable format other than a T-shirt, such as a glove, a headband, a wristband, a hat, or the like.
Moreover, the wearable member 80 includes the antenna 22 as an example of “wiring”. However, wiring with a function other than that of the antenna 22 may be interwoven into the fiber part 88.
Next, explanation follows regarding a fifth exemplary embodiment of technology disclosed herein.
In the fifth exemplary embodiment, the structure of the lower cover is modified from that of the first exemplary embodiment described above in the following manner. Namely, as illustrated in
As illustrated in
The fiber part 108 includes a high strength region 122, radio-wave permeable regions 124, and opening-formed regions 126. The high strength region 122, the radio-wave permeable region 124, and the opening-formed region 126 respectively form the high strength portion 102, the radio-wave permeable portion 104, and the opening-formed portion 106 (see
The high strength region 122 is formed by changing the thread material used for the radio-wave permeable regions 124 and the opening-formed regions 126 adjacent to the high strength region 122 to a stronger thread material than that used for the radio-wave permeable region 124. Preferably, for example, carbon fibers or the like are used for the thread material of the high strength region 122.
The radio-wave permeable regions 124 are formed by changing the thread material used for the high strength region 122 adjacent to the radio-wave permeable regions 124 to a thread material that is permeable to radio waves. For example, a thread material formed from a material (with insulating properties) such as glass fibers or resin fibers that are permeable to radio waves is preferably employed as the thread material for the radio-wave permeable regions 124.
The opening-formed regions 126 are each formed with a hole 132, this being an example of an “opening” (see also
Note that the high strength region 122 is an example of an “adjacent region” to the radio-wave permeable regions 124 and the opening-formed regions 126, and the radio-wave permeable regions 124 and the opening-formed regions 126 are examples of “adjacent regions” to the high strength region 122.
Next, explanation follows regarding a manufacturing method of the lower cover 100 according to the fifth exemplary embodiment.
First, the fiber part 108, which is a knitted article, is formed, as illustrated in
The high strength region 122 is formed by changing the thread material used for the radio-wave permeable region 124 adjacent to the high strength region 122 to a stronger thread material than the thread material of the radio-wave permeable regions 124. Moreover, the radio-wave permeable regions 124 are formed by changing the thread material used for the high strength region 122 adjacent to the radio-wave permeable regions 124 to a thread material that is permeable to radio waves. Moreover, in the opening-formed regions 126, the holes 132 are formed by changing the knitting technique used for the high strength region 122 adjacent to the opening-formed regions 126 (see also
Then, similarly to in the first exemplary embodiment, the fiber part 108 is impregnated with the resin 116 to form a prepreg, and the prepreg is press molded. When this is performed, as illustrated from the left to the center of
Next, as illustrated in
The left, center, and right parts of
Next, explanation follows regarding operation and advantageous effects of the fifth exemplary embodiment.
As described in detail above, in the fifth exemplary embodiment, a knitted article formed by knitting thread material is employed as the fiber part 108 used in the lower cover 100, rather than a woven article formed by interweaving weft and warp. Accordingly, each region, such as the high strength region 122, the radio-wave permeable regions 124, and the opening-formed regions 126 can be disposed at freely selected locations according to their respective purposes. This thereby enables the degrees of freedom in the layout of the antenna and the holes 132 (positioning holes 134) to be improved, and also enables the rigidity and permeability to radio-waves of the lower cover 100 to be secured.
Moreover, the fiber part 108 is formed with the high strength region 122, the radio-wave permeable regions 124, and the opening-formed regions 126, thereby integrally forming the lower cover 100 with the high strength portion 102, the radio-wave permeable portions 104, and the opening-formed portions 106. The forming of connection portions for plural members in the lower cover 100 is accordingly avoided, thus enabling the strength of the lower cover 100 to be secured.
Since the lower cover 100 can be integrally formed including the high strength portion 102, the radio-wave permeable portions 104, and the opening-formed portions 106, the number of components can be reduced, and a reduction in costs can be achieved, in comparison to, for example, cases in which the lower cover 100 is formed from plural members.
In each opening-formed region 126 of the fiber part 108, the hole 132 is pre-formed by changing the knitting technique at a region adjacent to the opening-formed region 126 (see
Moreover, as illustrated in
Next, explanation follows regarding modified examples of the fifth exemplary embodiment.
As illustrated in
Moreover, as illustrated by the upper part of
As illustrated in
In the example illustrated in
When the hole 132 is formed in the plural layers 142 by a single operation in this manner, misalignment of the position of the hole 132 between the plural respective layers 142 can be suppressed. Moreover, since misalignment of the plural layers 142 with respect to each other can be suppressed, stylistic quality can also be secured.
In the fiber part 108 according to the fifth exemplary embodiment, a general region, this being an example of an “adjacent region”, and at least one out of the high strength region 122, the radio-wave permeable region 124, the opening-formed region 126, and the resin region 128, may be combined as desired. Moreover, the sequence for forming the respective regions may also be freely set.
Moreover, in the fifth exemplary embodiment, instead of the hole described above, a notch may be formed as an example of an “opening”.
Moreover, in the fifth exemplary embodiment, the fiber part 108 is impregnated with the resin 116 that serves as a resin matrix (see
Next, explanation follows regarding a sixth exemplary embodiment of the technology disclosed herein.
An electronic device 150 according to the sixth exemplary embodiment illustrated in
The wearable member 160 includes a fiber part 168, which is a knitted article.
The fiber part 168 includes a general region 170 and a high strength region 172 (see also
The high strength region 172 is formed by changing the thread material used for the general region 170 adjacent to the high strength region 172 to a thread material with higher strength than the thread material of the general region 170. For example, resin-coated carbon fiber, twisted threads of carbon fiber twisted together with resin threads such as a polyamide, or knitted threads in which resin threads such as polyamide are intertwined with carbon fibers by French knitting, are preferably employed as the thread material of the high strength region 172. Moreover, a thermoplastic resin or a thermosetting resin is employed for the resin coating.
A support portion 174 is formed on a section of the high strength region 172 (see also
Next, explanation follows regarding operation and advantageous effects of the sixth exemplary embodiment.
In the sixth exemplary embodiment, the fiber part 168 of the wearable member 160 is formed from a knitted article. The general region 170 and the high strength region 172 can be integrally formed in the fiber part 168, thereby enabling a reduction in costs.
Moreover, the support portion 174 is formed in the high strength region 172, and components such as the unit 164 can be fixed to the support portion 174. An attachment member to attach such components is thereby rendered unnecessary, enabling a reduction in the number of components, and enabling a reduction in costs.
The support portion 174 for attaching the unit 164 is formed in the high strength region 172, enabling rigidity around the support portion 174 to be secured. Accordingly, positional displacement of the support portion 174 can be suppressed even in a state in which the unit 164 is attached to the support portion 174.
The support portion 174 and the high strength region 172 are formed integrally to the fiber part 168, thereby enabling a sense of cohesion when the wearable member 160 is being worn, as well as enabling an improvement in the ease of design.
Note that in the sixth exemplary embodiment, the wearable member 160 may be configured in a wearable format other than a T-shirt, such as a glove, a headband, a wristband, a hat, or the like.
Moreover, the fiber part 168 of the wearable member 160 may include at least one out of a high strength region, a radio-wave permeable region, an opening-formed region, or a resin region, similarly to the fiber part 108 of the lower cover 20 of the fifth exemplary embodiment described above (see
Moreover, the fiber part 168 of the wearable member 160 may include plural layers 142 (see
Moreover, combinable exemplary embodiments out of the first to the sixth exemplary embodiments described above may be implemented in appropriate combinations with each other.
Explanation has been given regarding the first to the sixth exemplary embodiments of technology disclosed herein. However, technology disclosed herein is not limited to the above, and obviously various modifications may be implemented within a range not departing from the spirit of the technology disclosed herein.
All cited documents, patent applications, and technical standards mentioned in the present specification are incorporated by reference in the present specification to the same extent as if the individual cited documents, patent applications, or technical standards were specifically and individually incorporated by reference in the present specification.
All examples and conditional language provided herein are intended for the pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although one or more embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
This application is a continuation application of International Application No. PCT/JP2014/076448, filed on Oct. 2, 2014, the disclosure of which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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Parent | PCT/JP2014/076448 | Oct 2014 | US |
Child | 15448893 | US |