Electronic apparatus display housing assembly

According to one embodiment, an electronic apparatus comprises a first case includes a screw hole, a second case separated from the first case, and a screw passing through the screw hole to fix the second case to the first case. The first case comprises a metallic portion includes an opening portion, a resin portion formed integrally with the metallic portion so as to cover the opening portion, a protrusion extending from the metallic portion to be arranged on the resin portion in a thickness direction, and a sheet-type block located between the protrusion and resin portion. The protrusion comprises an opening formed in a surface opposed to the resin part, and the screw hole extending from the opening to pass through the protrusion in the thickness direction, and the block covers the opening.

REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2010-117602, filed May 21, 2010; the entire contents of which are incorporated herein by reference.

FIELD

Embodiments described herein relate generally to an electronic apparatus comprising a housing formed by integrating a metal part with a resin portion into one body.

BACKGROUND

In an electronic apparatus, such as a notebook personal computer, a mobile phone, or a portable music player, a resin is used as a material of a housing for weight saving, aesthetics, and insulation purposes. Further, to achieve better strength than a housing made of a resin only, a housing is often made by integrating a metal and a resin.

In contrast, an electronic apparatus in demand on the market is smaller, thinner and lighter. Therefore, there is always a demand for size reduction of this type of electronic apparatus, and there is a certain need for a technique that realizes a smaller housing.

DETAILED DESCRIPTION

In general, according to one embodiment, an electronic apparatus comprises: a first case comprising a screw hole; a second case separated from the first case; and a screw passing through the screw hole to fix the second case to the first case. The first case comprises: a metallic portion comprising an opening portion; a resin portion formed integrally with the metallic portion so as to cover the opening portion; a protrusion extending from the metallic portion to be arranged on the resin portion in a thickness direction; and a sheet-type block located between the protrusion and resin portion. The protrusion comprises an opening formed in a surface opposed to the resin part, and the screw hole extending from the opening to pass through the protrusion in the thickness direction, and the block covers the opening.

Referring toFIGS. 1 to 6, a first embodiment of an electronic apparatus will be described below. In this specification, the near side to the user (that is, user side) is defined as front F, the far side from the user is rear R, the left-hand side of the user is left, the right-hand side of the user is right, the upper side from the user's position is up and the lower side from the user's position is down.

As shown inFIG. 1, a portable computer11, which is an example of the electronic apparatus, comprises a main body12and a display unit13. The main body12comprises a hinge14, and the hinge14rotatably supports the display unit13.

As shown inFIGS. 1 and 2, the main body12comprises a box-shaped main body cabinet15made of a metal such as a magnesium alloy, a keyboard16attached to an top surface of the main body cabinet15, a touch pad17provided on the top surface of the main body cabinet15, and a printed wiring board18contained in the main body cabinet15. The printed wiring board18comprises circuit components such as a CPU, RAM and ROM, and correctively controls the whole portable computer11. The main body cabinet15comprises an upper case15A which forms the upper half of the main body cabinet15and to which the keyboard16is fixed and a lower case15B which forms the lower half of the main body cabinet15.

The display unit13comprises a display21, a plastic display cabinet22surrounding the periphery of the display21, and a plurality of cushions24attached to a mask23of the display cabinet22. The display21is, for example, a liquid crystal display in the present embodiment, but may be another type of display panel.

As shown inFIGS. 1 and 5, the cushions24are made of an elastic material such as rubber. The cushions24are fixed to the mask23, which is a second case of the display cabinet22, at positions corresponding to heads25A of screws25described later. The cushions24are configured to strike the main body12when the display unit13is rotated to a position in which the display unit13covers the main body12, i.e., a position in which the mask23is opposed to the main body12. In the present embodiment, the main body cabinet15and the display cabinet22form a housing26.

As shown inFIG. 5, the display cabinet22comprises a cover31which is a first case covering a back surface of the display21, a mask23, which is a second case covering a front surface of the display21, and a screw25for fixing the mask23to the cover31. The mask23is provided separately from the cover31, and made of, for example, plastic to take a flat frame form. As shown inFIG. 5, the mask23comprises a through-hole23A through which a boss46(described later) of the cover31and the screw25pass.

As shown inFIG. 2, the cover31is formed by integrally providing synthetic resin on part of a metallic base, and takes a plate form as a whole. That is to say, as shown inFIGS. 2 and 5, the cover31comprises a metallic portion32in which an opening portion32A is provided, a resin portion33provided integrally with the metallic portion32to cover the opening portion32A, a first protrusion34and second protrusion35extending from the metallic portion32to the resin portion33, and a sheet-like block36made to adhere to the first protrusion34. The metallic portion32is made, for example, of magnesium alloy, but may be made of another metallic material.

The resin portion33is an antenna cover. On the inside of the resin portion33, a plurality of antennas are provided. The resin portion33is formed integrally with the metallic portion32by insert molding using the metallic portion32as an insert. The resin portion33is made of a synthetic resin material. As shown inFIGS. 2,3and6, the resin portion33comprises a main portion41, a plurality of first holders42protruding from the main portion41, and a plurality of second holders43protruding from the main portion41. Each of the first holders42protrudes from the main portion41to surround a first end34A of the first protrusion34or a second end35A of the second protrusion35. Each first holder42forms a bag shape together with the main portion41.

Each of the second holders43protrudes from the main portion41to surround the vicinity of a second base35B opposite to the second end35A of the second protrusion35. Each second holder43forms a tubular shape together with the main portion41.

As shown inFIG. 3, the first protrusion34is formed integrally with the metallic portion32, and is a small piece protruding toward the resin portion33. As shown inFIG. 5, the first protrusion34is arranged on the resin portion33in a thickness direction T of the resin portion33. As shown inFIGS. 3 and 5, the first protrusion34comprises a boss46on a surface45opposite to a surface44opposed to (facing) the resin portion33. As shown inFIGS. 4 and 5, the first protrusion34is provided with an opening47provided in the surface opposed to the resin portion33and a screw hole48extending from the opening47to pass through the boss46of the first protrusion34in the thickness direction T. The surface44of the first protrusion34, which is opposed to the resin portion33, is provided with a concave portion51, for example, having a depth of approximately 0.1 mm for arrangement of the block36. The block36is fitted in the concave portion51.

As shown inFIG. 6, the second protrusion35is integral with the metallic portion32, and is a small piece protruding toward the resin portion33. The second protrusion35is arranged on the resin portion33in the thickness direction T of the resin portion33. The second protrusion35is not provided with the boss46or screw hole48. As shown inFIG. 2, the first protrusions34and the second protrusions35are alternately provided at regular intervals in a width direction W of the cover31orthogonal to an anteroposterior direction of the portable computer11.

As shown inFIG. 5, the block36is interposed between the first protrusion34and the resin portion33. The block36is an example of an interposed portion interposed between the first protrusion34and the resin portion33. The block36is made of, for example, a heat-resistant tape having a thickness of approximately 0.1 mm. More specifically, the block36is a Kapton (registered trademark) tape, which is made by applying a silicone adhesive to one surface of a heat-resistant polyimide film. The block36covers the opening47of the first protrusion34.

To manufacture the cover31of the portable computer11of the present embodiment, the metallic portion32, first protrusion34and second protrusion35are integrally formed in advance by die-casting. Then, as shown inFIG. 5, a pilot hole passing through the boss46of the first protrusion34in the thickness direction T is formed, and the screw hole48(female thread) is formed along the pilot hole using a tap (not shown). Since the screw hole48passes through the first protrusion34in the thickness direction T, a screw thread can be formed on the entire inner surface of the screw hole48. Then, a heat-resistant tape, which is the block36, is made to adhere to the surface44opposed to the resin portion33of the first protrusion34to cover the opening47in the surface44. The metallic portion32, first protrusion34, second protrusion35and block36integrated into one body are located as an insert in a die for injection molding. In this state, injection molding is performed to form the resin portion33integrated with the metallic portion32. Since the opening47is covered by the block36, synthetic resin never enters the screw hole48. Further, since the block36is hidden under the resin portion33, provision of the block36does not spoil the appearance of the portable computer11.

According to the first embodiment, the portable computer11comprises the first case in which the screw hole48is provided, the second case separated from the first case, and the screw25which passes through the screw hole48to fix the second case to the first case; the first case comprises the metallic portion32in which the opening portion32A is provided, the resin portion33formed integrally with the metallic portion32to cover the opening portion32A, the protrusion extending from the metallic portion32to be arranged on the resin portion33in the thickness direction, and the block36located between the protrusion and the resin portion33; the protrusion is provided with the opening47formed in the surface44opposed to the resin portion33and the screw hole48extending from the opening47and passing through the protrusion in the thickness direction T; and the block36covers the opening47.

Generally, when a screw hole (female thread) having a bottom is formed by means of a tap, the female thread cannot be formed in an area within, for example, approximately 0.6 mm of the bottom of a pilot hole because of the structure of the tap. This is because the female screw cannot be formed in the vicinity of the tip of the tap. Moreover, when a screw hole having a bottom is formed, the thickness of a bottom part needs to be at least, for example, 0.6 mm or thereabouts in consideration of, for example, tolerance of the pilot hole. Therefore, in the case of a general screw having a bottom, a dimensional loss of, for example, approximately 1.2 mm or more is produced by combination of the above causes.

Since the screw hole48is formed to pass through the protrusion in the above structure, the effective length of the screw, which is the length of the area in the screw hole48where a female thread is actually formed, is equal to the entire length of the screw hole48. Accordingly, the entire length of the screw hole48can be reduced, and the thickness of the first case can be reduced. Further, since the bottom part of the screw hole48need not be provided, the thickness of the first case can be further reduced by the thickness of the bottom part. Consequently, the thickness of the portable computer11can be further reduced.

In addition, since the opening47is covered by the block36, it is possible to prevent a resin from entering the screw hole48and filling the screw hole48when the resin portion33is formed integrally with the metallic portion32. Further, since the block36takes a sheet form, the thickness of the first case is not increased by provision of the block36. In particular, if a sheet having a thickness of, for example, 0.1 mm or thereabouts is used as the block36, the thickness of the first case can be reduced by, for example, at least 1.1 mm or thereabouts. Consequently, the thickness of the portable computer11can be reduced by that length.

In this case, the metallic portion32is provided with the concave portion51in which the block36is fitted. This structure can prevent the thickness of the resin portion33from being thinner by provision of the block36. Consequently, the fluidity of the resin at the time of injection molding is improved, and the frequency of producing a defective resin portion33can be reduced. As a result, the yield of the first case can be improved.

The resin portion33comprises the first holders42which surround and hold the end part of the protrusion. This structure can improve the strength around the resin portion33. Consequently, even if the thickness of the first case is further reduced, it is possible to prevent the strength around the resin portion33from being reduced.

In this case, the portable computer11comprises the main body12provided separately from the first case and second case and rotatably supporting the first case and second case, and the cushions24which are fixed to the second case at positions corresponding to the heads25A of the screws25and strikes the main body12when the second case is rotated to be opposed to the main body12. Since the cushions24are provided in correspondence with the heads25A of the screws25in this structure, the second case can be prevented from striking hard against the main body12. Further, the heads25A of the screws25can be hidden under the cushions24, and good appearance of the portable computer11can be maintained. Therefore, it is preferable to provide the cushions24to the portable computer11.

Next, referring toFIG. 7, a second embodiment of the electronic apparatus will be described. The portable computer11which is an example of the electronic apparatus of the second embodiment is different from that of the first embodiment in that the first holder42and the second holder43are provided in correspondence with the first protrusion34. However, the other elements are the same as those of the first embodiment. Therefore, different elements will mainly be explained, and the same elements will be assigned the same reference symbols, and the explanations thereof will be omitted. The portable computer11of the second embodiment has the same appearance as that shown inFIG. 1.

The resin portion33comprises a main portion41, a plurality of first holders42protruding from the main portion41, and a plurality of second holders43protruding from the main portion41. Each first holder42surrounds the first end34A of the first protrusion34or the second end35A of the second protrusion35. Each first protrusion42forms a bag shape together with the main portion41. Each second holder43surrounds the vicinity of the second base34B opposite to the first end34A of the first protrusion34, or surrounds the vicinity of the second base35B opposite to the second end35A of the second protrusion35. Each second protrusion43forms a tubular shape together with the main portion41.

In this second embodiment, the first protrusion42and the second protrusion43are provided in correspondence with the first protrusion34. Between the first holder42and the second holder43, the boss46and screw hole48of the first protrusion34are provided.

In the second embodiment, the protrusion comprises the base portion opposite to the end portion, and the resin portion33comprises the second holder43surrounding and holding the base portion. Since the second holder43is provided in addition to the first holder42in this structure, the strength of the resin portion33around the first protrusion34can be further improved. Even if the thickness of the portable computer11is further reduced, the strength of the first case of the resin portion33can be prevented from being reduced.

Referring toFIGS. 8 and 9, we will explain a third embodiment of the electronic apparatus. The portable computer11which is an example of the electronic apparatus of the third embodiment is different from that of the first embodiment in terms of the forms of the first protrusion34and block36. However, the other elements are the same as those of the first embodiment. Therefore, different elements will mainly be explained, and the same elements will be assigned the same reference symbols, and the explanations thereof will be omitted. The portable computer11of the third embodiment has the same appearance as that shown inFIG. 1.

As shown inFIG. 8, the first protrusion34is integrated with the metallic portion32, and is a small piece protruding toward the resin portion33. The first protrusion34comprises the boss46on the surface45opposite to the surface44opposed to the resin portion33. The first protrusion34is provided with the opening47provided in the surface44opposed to the resin portion33, and the screw hole48extending from the opening47and passing through the boss46of the first protrusion34in the thickness direction T. The surface44opposed to the resin portion33of the first protrusion34is provided with a concave portion51having a depth of, for example, approximately 0.1 mm for disposition of the block36. The block36is fitted in the concave portion51.

The first protrusion34comprises an insertion portion61having a hook-shaped cross section, in which a first end36A of the block36, which will be mentioned later, is inserted. The insertion portion61can hold therein the first end36A of the block36.

As shown inFIG. 9, the block36is formed by bending a sheet-like metallic plate having a thickness of, for example, approximately 0.1 mm. More specifically, the block36is made by bending an aluminum plate by sheet metal processing. The composition of the aluminum plate is, for example, pure aluminum. Instead of pure aluminum, various aluminum alloys may be used.

The block36comprises a first end36A and a second end36B opposite to the first end36A. The second end36B is bent, for example, to form a U-shape along the first end34A of the first protrusion34. The block36covers the opening47of the first protrusion34.

To manufacture the cover31of the portable computer11of the present embodiment, the metallic portion32, first protrusion34and second protrusion35are integrally formed in advance by die casting. Then, as shown inFIG. 8, a pilot hole passing through the boss46of the first protrusion34in the thickness direction T is formed, and the screw hole48(female thread) is formed along the pilot hole using a tap (not shown). At this time, the thread is formed on the entire inner surface of the screw hole48. The aluminum plate, which is the block36, is subjected to bending work in advance to have a U-shaped cross section as indicated by a chain double-dashed line inFIG. 9. The aluminum plate is mounted on the surface44opposed to the resin portion33of the first protrusion34to cover the opening47in the surface44. At the same time as inserting the first end36A of the block36into the insertion portion61, the second end36B of the block36is inserted into the first end34A of the first protrusion34, whereby the block36is fixed to the first protrusion34. Further, the metallic portion32, first protrusion34, second protrusion35and block36integrated into one body are located as an insert in a die for injection molding. In this state, injection molding is performed to form the resin portion33integrated with the metallic portion32. Since the opening47is blocked by the aluminum plate, which is the block36, synthetic resin never enters the screw hole48.

In the third embodiment, since the block36is made of an aluminum plate, the costs for manufacturing the block36can be reduced in comparison with the first embodiment in which an expensive heat-resistant tape (Kapton [registered trademark] tape) is used.

The electronic apparatus is not limited to the portable computer11described in the above embodiments, and may be another electronic apparatus such as a mobile phone. The electronic apparatus may be variously modified within the spirit of the invention at the stage of implementation. Further, the invention is variously embodied by appropriately combining a plurality of structural elements disclosed in the above descriptions of embodiments. For example, some structural elements may be omitted from all the structural elements disclosed in the above descriptions of embodiments. Moreover, structural elements in different embodiments may be combined where necessary.