The present invention relates to a method for manufacturing a structure which includes (i) a casing made of a dielectric and (ii) a conducting member embedded in the casing so as to be through the casing, the method being used for, for example, a casing of a mobile phone.
Recent electronic devices such as a mobile phone have been required to be highly functional while being small. Accordingly, components of such electronic devices are also required to be highly accurate and highly functional. A known method for preparing such highly accurate and highly functional components is exemplified by insert molding. Insert molding is a method for integrally molding a conducting member and a resin by inserting the conducting member into a mold and filling, with a molten resin, a portion around the conducting member inside the mold, and then solidifying the molten resin.
A method for manufacturing a component by insert molding is exemplified by a method disclosed in Patent
A method for manufacturing a component by insert molding is exemplified by a method disclosed in Patent Literature 1 for manufacturing a component for a pressure switch. The component for a pressure switch which component is disclosed in Patent Literature 1 is molded so that a connection terminal made of a metal plate is embedded in a resin terminal base.
According to the method for manufacturing a component for a pressure switch, a standing part 201 of the connection terminal 200 is inserted into a recess of an upper mold 220, whereas a part of the connection terminal 200 which part is on an opposite side of the standing part 201 is arranged so as to be pressed against a lower mold 221 (see
Patent Literature 1
Japanese Patent Application Publication, Tokukai, No. 2006-185599 A (Publication Date: Jul. 13, 2006)
According to the component for a pressure switch which component is disclosed in Patent Literature 1, the standing part 201 of the connection terminal 200 is used to fix the connection terminal 200 in the mold. Note here that the standing part 201, which is a member protruding from a terminal base 210, can be used to fix the connection terminal 200 in the mold. However, the method described in Patent Literature 1 causes problems (i) such that it is impossible to fix, in a mold, a metallic component having no part that protrudes from a resin part and (ii) such that a terminal cannot have a flat surface due to a member provided to protrude on the terminal side, so that a contact surface of the terminal is small.
The present invention has been made in view of the problems, and an object of the present invention is to provide a manufacturing method which makes it possible to (i) manufacture, by insert molding, a structure including a metallic component having no part that protrudes from a resin part and (ii) sufficiently secure a contact surface of the structure.
In order to attain the object, the present invention is a method for manufacturing a structure which includes (i) a casing made of a dielectric and (ii) a conducting member embedded in the casing so as to be through the casing, the method including: a first step of fixing a conducting member in a mold; and a second step of forming the casing by filling the mold with a dielectric material and solidifying the dielectric material, the conducting member being provided with a recess, and the mold being provided with a protrusion corresponding to the recess, and in the first step, the conducting member being fixed in the mold by fitting the protrusion of the mold in the recess of the conducting member.
According to the configuration, the conducting member is provided with the recess, and the mold is provided with the protrusion corresponding to the recess. In the first step, the conducting member is fixed in the mold by fitting the protrusion of the mold in the recess of the conducting member. According to this, the conducting member, which has no protrusion that protrudes from the casing, can also be fixed in the mold and manufactured by insert molding. In other words, since a structure manufactured by the method for manufacturing a structure of the present embodiment has no protrusion that protrudes from the casing, a thickness of the structure itself can be made thin.
Furthermore, a second surface of the conducting member which second surface is opposite from a first surface of the conducting member of the structure on which first surface the recess is provided is not involved in fixing of the conducting member. This allows the second surface to be flat, so that the conducting member can have a sufficiently secured surface of a contact with another circuit.
The present invention is a method for manufacturing a structure which includes (i) a casing made of a dielectric and (ii) a conducting member embedded in the casing so as to be through the casing, the method comprising: a first step of fixing a conducting member in a mold; and a second step of forming the casing by filling the mold with a dielectric material and solidifying the dielectric material, the conducting member being provided with a recess, and the mold being provided with a protrusion corresponding to the recess, and in the first step, the conducting member being fixed in the mold by fitting the protrusion of the mold in the recess of the conducting member. This yields an effect such that the conducting member, which has no protrusion that protrudes from the casing, can also be fixed in the mold and manufactured by insert molding.
(a) through (c) of
(a) through (d) of
(Structure)
The following will first discuss a structure which is manufactured in accordance with a manufacturing method of an embodiment of the present invention.
The casing 1 is made of a dielectric and constitutes a casing of an electronic device. The casing of the electronic device refers to a member in which an electronic component of the electronic device is stored. The conducting member 2, which is a conducting material that is embedded in the casing 1 so as to be through the casing 1, electrically connects regions between which the casing 1 is provided (e.g., an upper side of the casing 1 shown in
It is assumed in the following description that the structure 10 has a first surface corresponding to an outer surface of the casing 1 and a second surface corresponding to an inner surface of the casing 1. It is also assumed that the casing 1 has a surface 1a corresponding to the first surface and a surface 1b corresponding to the second surface. The conducting member 2, which is through the casing 1, has exposed surfaces on the respective first and second surfaces. It is assumed that the exposed surface on the first surface of the conducting member 2 is a surface 2a and the exposed surface on the second surface of the conducting member 2 is a surface 2b.
The conducting pattern 3 is a conducting film which is provided on the first surface of the structure 10 so as to be in contact with the conducting member 2. The conducting pattern 3 is a conducting film which has no shape retention in itself (has no self shape retention). For example, the conducting pattern 3 can be a flexible conducting film such as a flexible printed circuit board or a conducting film formed by applying conducting paste.
Conducting paste, which is a viscous conducting material, at least contains metal powder and a solvent, and preferably contains metal powder, a binder resin, and a solvent. For example, according to a conducting film formed by applying conducting paste, a solvent may be removed by drying from the conducting film, or a part of the solvent may remain in the conducting film.
It is possible to employ various methods for applying conducting paste. However, conducting paste is preferably applied by printing by use of a flexible printing plate (e.g., flexsographic printing, offset printing, silk-screen printing, pad printing, or the like) so as to be suited to shapes of the casing 1 and the conducting member 2.
The surface 2b of the conducting member 2 which surface 2b is opposite from the surface 2a on which the conducting pattern 3 is provided is in electrical contact with a terminal (e.g., a spring terminal 20) provided in the casing 1. The conducting pattern 3 is in electrical contact with another member via the conducting member 2 and the spring terminal 20.
The structure 10 thus configured can be embedded in, for example, a communication device.
The casing 1 is a casing of the communication device 100 (see
The spring terminal 20 is connected via a feed line 21 with the communication circuit 30 of the communication device 100. According to the communication device 100, the conducting pattern 3, which is fed by the communication circuit 30 via the feed line 21, the spring terminal 20, and the conducting member 2, operates as an antenna. In this case, the surface 2b of the conducting member 2 serves as an electrode to be connected with the feed line 21 via which the conducting pattern 3 is fed.
Note that the casing 1 and the conducting pattern 3 do not necessarily need to be exposed on a surface of the communication device 100 but may also be stored in the communication device 100. Note also that the conducting pattern 3 does not necessarily need to function as an antenna but may also function as a conducting member which allows a member connected with the spring terminal 20 to be electrically connected via the conducting pattern 3 to a member provided on the outside of the casing 1.
The conducting member 2 can be, for example, columnar, and preferably pin-shaped. Note that a pin shape refers to a shape such that a length in a direction in which the conducting member 2 is through the casing is longer than a width in a direction perpendicular to the direction in which the conducting member 2 is through the casing. Note that the conducting member 2 may have not only a cylindrical shape but also a prism shape. Further, the conducting member 2 does not need have a uniform thickness.
Furthermore, the conducting pattern 3 is not particularly limited in shape. It is possible to appropriately set a shape of the conducting pattern 3 in accordance with, for example, design of the structure 10 and the communication device 100. For example, the conducting pattern 3 may have a shape which covers only a part of the surface 2a of the conducting member 2 (see
According to an embodiment of the present invention, the communication device 100 may further include a protective layer 4 provided on the conducting pattern 3 (see
(Method for Manufacturing Structure)
The method for manufacturing the structure 10 is described with reference to (a) through (c) of
The mold is constituted by an upper mold 40 and a lower mold 41. The conducting member 2 has a recess 2c on the surface 2a which is in contact with the upper mold 40. The upper mold 40 has a protrusion 40a.
In a case where the protrusion 40a of the upper mold 40 is fitted in the recess 2c of the conducting member 2, the conducting member 2 is positioned to be fixed in the mold (see (a) of
After the conducting member 2 has been positioned to be fixed in the mold, the dielectric material is filled via a filling hole (not illustrated) into the mold (see (b) of
After the dielectric material filled in the mold has been solidified to be the casing 1, the upper mold 40 and the lower mold 41 are removed, so that the structure 10 is obtained (see (c) of
For example, the conducting pattern 3 may be formed by, for example, applying conducting paste to the surface 1a and the surface 2a so that a desired pattern is formed, and then subjecting the conducting paste to, for example, drying. It is possible to employ various methods for applying conducting paste. However, conducting paste is preferably applied by printing by use of a flexible printing plate (e.g., flexsographic printing, offset printing, silk-screen printing, pad printing, or the like) so as to be suited to shapes of the casing 1 and the conducting member 2.
Further, the conducting pattern 3 which is constituted by a flexible printed circuit board can be formed by attaching the flexible printed circuit board to the surfaces 1a and 2a so that the flexible printed circuit is in contact with the conducting member 2.
Note that, in a case where the structure 10 including the protective layer 4 is formed (see
(Advantage of Present Embodiment)
The structure 10 of the present embodiment makes it possible to electrically connect the regions between which the casing 1 is provided. Further, according to an embodiment of the present invention, the conducting pattern 3 may be provided. The conducting pattern 3 may be used as an antenna, or may be used to be electrically connected with a member provided in a region in which the conducting pattern 3 is provided. Note here that according to an embodiment of the present invention, the conducting pattern 3 is a conducting film which has no shape retention in itself.
Therefore, the conducting pattern 3 can be fixed in a free shape. This brings about an advantage of increasing a degree of freedom of design.
According to an embodiment of the present invention, the conducting pattern 3 can be formed by application of the conducting paste. This allows the conducting pattern to be thin and easily allows the conducting pattern to have a curved surface shape. This allows a further increase in degree of freedom of design.
According to an embodiment of the present invention, the conducting paste can be applied by printing by use of a flexible printing plate (e.g., flexsographic printing, offset printing, silk-screen printing, pad printing, or the like). Therefore, the conducting pattern can be successfully printed in accordance with, for example, a shape of the casing. This contributes to, for example, mass production of a structure.
According to an embodiment of the present invention, the conducting pattern 3 can be constituted by a flexible conducting film such as a flexible printed circuit board. This also allows the conducting pattern 3 to be fixed in a free shape. Therefore, the degree of freedom of design can be increased.
According to the method for manufacturing the structure 10 of the present embodiment, the conducting member 2 is provided with the recess 2c, and the upper mold 40 is provided with the protrusion 40a corresponding to the recess 2c. Further, the conducting member 2 can be positioned to be fixed in the mold by fitting the protrusion 40a of the upper mold 40 in the recess 2c of the conducting member 2. According to this, the conducting member 2, which has no protrusion that protrudes from the casing, can also be fixed in the mold, so that the casing 1 can be manufactured by insert molding. In other words, since the structure 10 manufactured by the method for manufacturing the structure 10 of the present embodiment has no protrusion that protrudes from the casing 1, the structure 10 can be made thin.
Furthermore, in the case of the conventional technique in which the conducting member 2 has a protrusion for fixing the conducting member 2 in the mold, a disconnection of the conducting pattern 3 may occur around the protrusion. However, according to the present embodiment, the conducting member 2 has no protrusion for fixing the conducting member 2 in the mold. Therefore, the conducting pattern 3 which is electrically connected with the conducting member 2 can be easily formed in the structure 10 manufactured by the method of the present embodiment. Moreover, the surface 2b of the conducting member 2, which surface 2b is not involved in fixing of the conducting member 2, can be flat, so that the conducting member 2 can have a sufficiently secured surface of a contact with the spring terminal 20.
According to an embodiment of the present invention, the conducting pattern 3 is provided after fixing the casing 1 and the conducting member 2. Therefore, even if the conducting pattern 3 is constituted by a conducting film having no shape retention in itself (e.g., a conducting paste is a flexible printed circuit board), the conducting pattern 3 can be provided on the casing 1 and the conducting member 2 (the surface 1a and the surface 2a) with no difficulty.
According to the structure 10 of an embodiment of the present invention, since the conducting member 2 is made columnar, the conducting member 2 which is through the casing 1 can be suitably provided.
According to the structure 10 of an embodiment of the present invention, since the casing 1 and the conducting member 2 are integrally molded, the conducting member 2 can be preferably embedded in the casing 1.
According to an embodiment of the present invention, since the casing 1 is a casing of a communication device and the conducting pattern 3 is an antenna, the communication device having a higher degree of freedom of design of the antenna can be provided by using the conducting pattern as the antenna.
According to an embodiment of the present invention, since the surface 2b is used as an electrode to be connected with a feed line 21 via which the conducting pattern 3 is fed, it is possible to feed the conducting pattern 3 via the feed line 21 provided in the regions between which the casing 1 is provided. This makes it possible to provide the communication device having a higher degree of freedom of design of the antenna.
According to an embodiment of the present invention, since the protective layer 4 is formed on the conducting pattern 3, the conducting pattern 3 can have higher durability.
[Comparison with Other Configurations]
(a) of
(b) of
(c) of
(d) of
(e) of
(f) of
As described earlier, the configuration of the structure 10 of the present embodiment yields a more advantageous effect than the configurations illustrated in (a) through (f) of
[Additional Descriptions]
As described earlier, the present invention is a method for manufacturing a structure which includes (i) a casing made of a dielectric and (ii) a conducting member embedded in the casing so as to be through the casing, the method including: a first step of fixing a conducting member in a mold; and a second step of forming the casing by filling the mold with a dielectric material and solidifying the dielectric material, the conducting member being provided with a recess, and the mold being provided with a protrusion corresponding to the recess, and in the first step, the conducting member being fixed in the mold by fitting the protrusion of the mold in the recess of the conducting member.
According to the configuration, the conducting member is provided with a recess, and the mold is provided with a protrusion corresponding to the recess. In the first step, the conducting member is fixed in the mold by fitting the protrusion of the mold in the recess of the conducting member. According to this, the conducting member, which has no protrusion that protrudes from the casing, can also be fixed in the mold and manufactured by insert molding. In other words, since a structure manufactured by the method for manufacturing a structure of the present embodiment has no protrusion that protrudes from the casing, a thickness of the structure itself can be made thin.
Furthermore, a second surface of the conducting member which second surface is opposite from a first surface of the conducting member of the structure on which first surface the recess is provided is not involved in fixing of the conducting member. This allows the second surface to be flat, so that the conducting member can have a sufficiently secured surface of a contact with another circuit.
The method can be configured to further include: a third step, following the second step, of forming a conducting pattern so that the conducting pattern is electrically connected with the conducting member, the conducting pattern being provided on a first surface of the conducting member of the structure on which first surface the recess is provided.
In the case of the conventional technique in which the conducting member has a protrusion for fixing the conducting member in the mold, a disconnection of the conducting pattern may occur around the protrusion. However, according to the configuration, the conducting member has no protrusion for fixing the conducting member in the mold. Therefore, it is easy to carry out a process for, for example, forming, in the structure manufactured by the above method, a further conducting layer which is electrically connected with a surface of the conducting member.
The method can be configured such that in the third step, conducting paste is applied to the first surface of the conducting member of the structure on which first surface the recess is provided.
According to the configuration, the conducting pattern can be formed by application of the conducting paste. This allows the conducting pattern to be thin and easily allows the conducting pattern to have a curved surface shape. This allows a further increase in degree of freedom of design.
The method can be configured such that in the third step, the conducting paste is applied, by printing by use of a flexible printing plate, to the first surface of the conducting member of the structure on which first surface the recess is provided.
According to the configuration, the conducting material can be applied by printing by use of a flexible printing plate (e.g., flexsographic printing, offset printing, silk-screen printing, pad printing, or the like). Therefore, the conducting pattern can be successfully printed in accordance with, for example, a shape of the casing. This contributes to, for example, mass production of a structure.
The method can be configured such that: the casing is a casing of a communication device; and the conducting pattern is an antenna.
According to the configuration, the communication device having a higher degree of freedom of design of the antenna can be provided by using the conducting pattern as the antenna.
The method can be configured such that a second surface of the conducting member is electrically connected with another circuit, the second surface being opposite from the first surface of the conducting member on which first surface the recess is provided.
The method can be configured to further include a fourth step of forming a protective layer (attachment of a sheet material, coating with paint, or the like) on the conducting pattern.
According to the configuration, the conducting pattern can have higher durability. Further, the configuration allows the conducting pattern to be covered.
The method can be configured such that the conducting member is columnar.
According to the configuration, the conducting member which is through the casing can be suitably provided.
The present invention is not limited to the description of the embodiments described above, but may be altered within the scope of the claims. An embodiment based on a proper combination of technical means disclosed in different embodiments is encompassed in the technical scope of the present invention.
The present invention is applicable to, for example, manufacture of a casing of an electronic device.
Number | Date | Country | Kind |
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2011-177319 | Aug 2011 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2012/069253 | 7/27/2012 | WO | 00 | 11/27/2013 |