Abstract:
According to one embodiment, an electronic apparatus includes: an outer case formed of a thin metal plate and having a front plate and side plates surrounding the front plate, the side plate having a protrusion formed by bending an edge of the side plates inward of the outer case to prevent exposing the edge to exterior of the electronic apparatus; a middle member formed of a resin material and formed correspondingly to an inner surface of the outer case, the middle member having a side member that confronts the side plate, the side member having a retaining portion to engage with the protrusion; and a casing having a support portion and configured to confront an inside of the side member to keep the protrusion engaged with the retaining portion by preventing the side member from deflection.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2007-155580, filed Jun. 12, 2007, the entire contents of which are incorporated herein by reference. 
     BACKGROUND 
     1. Field 
     One embodiment of the invention relates to an electronic apparatus in which an outer case formed of a thin metal plate is mounted in an apparatus case, with a middle member formed of a resin material interposed therebetween. 
     2. Description of the Related Art 
     Recently, some electronic apparatuses, particularly, some portable electronic apparatuses have an apparatus case formed of a metal plate in order to realize the slimness and improve the strength (for example, see JP-A-2004-335644). 
     Moreover, there is provided a cellular phone which is an example of the electronic apparatus, in which an outer case formed of a metal plate is mounted outside the apparatus case in order to improve the strength, a sense of beauty, and a sense of touch. 
     As shown in  FIGS. 15 and 16 , a known cellular phone A includes a lower case B with several operational keys and the like, an upper case C with a liquid crystal display unit and the like, and a hinge H interposed therebetween so as to be opened and closed. 
     The upper case C of the cellular phone A is configured in a manner in which an outer case O formed of a thin metal plate by a press molding process is attached outside an upper inner case I made of a magnesium alloy, for example, with a middle case (middle member) M formed of a resin material interposed therebetween. 
     The outer case O includes a front plate of and side plates Os bent from the borders of the front plate Of. The middle case M also includes a top plate Mt and circumferential plates Ms bent from the borders of the top plate Mt. The middle case M is fixed to the inner surface of the outer case O using a strong adhesive or a double-sided adhesive tape. 
     Attachment bosses Mb are formed on the top plate Mt of the middle case M. In addition, the outer case O is fixed to the upper inner case I, with the middle case M interposed therebetween by screw-fixing the upper inner case I to the attachment bosses Mb. 
     Various circuit boards E are mounted in the upper inner case I, and a liquid crystal display unit L and a cover glass G are attached to the front surface of the upper inner case I (lower side of  FIG. 16 ). 
     In the outer circumferential border of the upper inner case I, a rib Ir is formed for covering an edge Oe of the outer case O formed of a thin metal plate in order to prevent the edge Oe of the outer case O from being exposed to the outside and from being damaged by user&#39;s fingers beforehand. 
     However, in the known cellular phone A described above, the edge Oe of each side plate Os of the outer case O is covered with the rib Ir formed in the outer circumferential border of the upper inner case I. For that reason, the rib Ir is exposed to the outside across the entire circumference of the side plates Os of the outer case O. Accordingly, even though the outer case O is made of metal, there occurs a problem in that design of the cellular phone becomes deteriorated. 
     Moreover, in the known cellular phone A, the middle case M and the outer case O are fixed with each other by the strong adhesive or the like, as described above. For that reason, when a large external force is applied to the outer case O against the adhesive force in a case where the middle case M and the outer case O are detached from each other in order to make repair, the outer case O formed of the thin metal plate becomes distorted. Accordingly, there occurs a problem in that the repair job is difficult. 
     SUMMARY 
     According to one aspect of the invention, there is provided an electronic apparatus including: an outer case formed of a thin metal plate and having a front plate and side plates surrounding the front plate, the side plate having a protrusion formed by bending an edge of the side plates inward of the outer case to prevent exposing the edge to exterior of the electronic apparatus; a middle member formed of a resin material and formed correspondingly to an inner surface of the outer case, the middle member having a side member that confronts the side plate, the side member having a retaining portion to engage with the protrusion; and a casing having a support portion and configured to confront an inside of the side member to keep the protrusion engaged with the retaining portion by preventing the side member from deflection. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       A general architecture that implements the various feature of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. 
         FIG. 1  is an exemplary perspective view illustrating an outer appearance of a cellular phone as an example of an electronic apparatus according to an embodiment. 
         FIGS. 2(   a ),  2 ( b ), and  2 ( c ) are an exemplary front view, an exemplary side view, and an exemplary end view illustrating the cellular phone shown in  FIG. 1 , respectively. 
         FIG. 3(   a ) is an exemplary top view illustrating an outer case of an upper case in the cellular phone shown in  FIG. 1 .  FIG. 3(   b ) is an exemplary side view illustrating the outer case.  FIG. 3(   c ) is an exemplary end view illustrating a liquid crystal display of the cellular phone. 
         FIG. 4  is an exemplary sectional view taken along the line IV-IV shown in  FIG. 3 . 
         FIG. 5  is an exemplary exploded view illustrating the outer case, a middle member, and an upper inner case constituting the upper case in the cellular phone shown in  FIG. 1 . 
         FIG. 6  is an exemplary exploded view illustrating the outer case, a middle member, and the upper inner case constituting the upper case in the cellular phone shown in  FIG. 1 . 
         FIG. 7  is an exemplary end view illustrating the outer case, a middle member, and the upper inner case constituting the upper case in the cellular phone shown in  FIG. 1 . 
         FIG. 8(   a ) is an exemplary end view illustrating the sectional surface of major elements in a state where the outer case constituting the upper case in the cellular phone shown in  FIG. 1  is mounted in the middle member.  FIG. 8(   b ) is an exemplary end view illustrating the sectional surface of major elements in a state where the outer case and the middle member incorporated with each other is mounted in an apparatus case. 
         FIG. 9  is an exemplary perspective view illustrating an outer appearance of a cellular phone as an example of an electronic apparatus according to another embodiment of the invention. 
         FIG. 10  is an exemplary end view illustrating the sectional surface of the upper case in the cellular phone shown in  FIG. 9 . 
         FIG. 11(   a ) is an exemplary end view illustrating the sectional surface of major elements in a state where an outer case constituting the upper case in the cellular phone shown in  FIG. 9  is mounted in a middle member.  FIG. 11(   b ) is an exemplary end view illustrating the sectional surface of major elements in a state where the outer case and the middle member incorporated with each other is mounted in an apparatus case. 
         FIGS. 12(   a ),  12 ( b ), and  12 ( c ) are an exemplary front view, an exemplary side view, and an exemplary end view illustrating a cellular phone as an example of an electronic apparatus according to other embodiment, respectively. 
         FIG. 13(   a ) is an exemplary top view illustrating an outer case viewed from the outside.  FIG. 13(   b ) is an exemplary top view illustrating the outer case mounted with a middle member viewed from the inside. 
         FIG. 14(   a ) is an exemplary sectional view taken along the line a-a shown in  FIG. 13 .  FIG. 14(   b ) is an exemplary sectional view taken along the line b-b shown in  FIG. 13 . 
         FIG. 15  is an exemplary perspective view illustrating a known cellular phone as an electronic apparatus. 
         FIG. 16  is an exemplary end view illustrating the sectional surface of an upper case in the cellular phone shown in  FIG. 15 . 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, embodiments of the invention will be described in detail with reference to the drawings. 
       FIGS. 1 to 8  are diagrams illustrating a cellular phone, which is one example of an electronic apparatus, according to an embodiment of the invention. As shown in  FIGS. 1 and 2 , a cellular phone  1  includes a lower case  2  forming a main body and an upper case  3  forming a cover body. The lower case  2  and the upper case  3  are connected to each other so as to be opened and closed, with a connection body  4  having a rotatable two-pivotal hinge mechanism (not shown) interposed therebetween, and moreover they are pivotably connected to each other about a pivot shaft perpendicular to an opening/closing shaft. 
     As shown in  FIG. 3 , the upper case  3  of the cellular phone  1  has an outer shape similar to a very flat rectangle. A large main liquid crystal screen  3   m , an ear piece  3   r , and the like are provided on a front surface of the upper case  3  and a small sub-liquid crystal screen  3   s  is provided on a rear surface of the upper case  3 . 
     As shown in  FIG. 4 , the upper case  3  of the cellular phone  1  includes an upper inner case (apparatus case)  3 I made of a magnesium alloy, for example, a middle case (middle member)  3 M formed of a resin material, and an outer case  3 O formed by a press molding process with a thin metal plate. The outer case  3 O is mounted on the outside of the upper inner case  3 I, with the middle case  3 M interposed therebetween. 
     In the inside of the upper case  3 , a board  3   e  is mounted on the upper inner case  3 I. In addition, a liquid crystal display unit  3   l  and a cover glass  3   g  are attached to the front surface of the upper inner case  3 I (lower side of  FIG. 4 ). 
     As shown in  FIGS. 4 to 7 , the outer case  3 O forming a part of the upper case  3  includes a front plate  3 Of formed in a substantially rectangular plane shape and side plates  3 Os bent from the border portion of the front plate  3 Of. An opening  3 Oo for the sub-liquid crystal screen  3   s  (see  FIGS. 1 to 3 ) is formed in the front plate  3 Of. 
     In the lower border of the side plates  3 Os of the outer case  3 O, an edge of the metal plate is subjected to a bending process so as to be inward formed in L-shaped cross section with respect to each side plate  3 Os so that the edge of the metal plate is not exposed outward. In addition, the protrusion  3 Op which protrudes in an inward direction of each side plate  3 Os is formed by the border portion subjected to the bending process. 
     On the other hand, the middle case  3 M forming a part of the upper case  3  includes a top plate  3 Mt corresponding to the front plate  3 Of of the outer case  3 O and circumference plates  3 Ms bent from the borders of the top plate  3 Mt. An engagement claw (engagement portion)  3 Mp which engages with the protrusion  3 Op of the above-described outer case  3 O is formed on the outer surface of each circumference plate  3 Ms. 
     The middle case  3 M is intruded and fixed to the outer case  3 O by fitting the middle case  3 M corresponding to the inner surface of the above-described outer case  3 O and engaging each engagement claw (engagement portion)  3 Mp with each protrusion  3 Op of the outer case  3 O. 
     The front plate  3 Of of the outer case  3 O and the top plate  3 Mt of the middle case  3 M are adhered to each other by a double-sided adhesive tape (not shown) with weak adhesion, which is effective in fixing the middle case  3 M to the outer case  3 O. 
     On the other hand, the upper inner case  3 I forming a part of the upper case  3  has a substantially rectangular plane shape corresponding to the outer case  3 O and the middle case  3 M described above. In addition, the upper inner case  3 I is screw-fixed to an attachment boss (not shown) formed in the middle case  3 M so as to be integrally formed with the outer case  3 O and the middle case  3 M. 
     In the outer circumference border of the upper inner case  3 I, there is formed a stepped portion  3 Ir in which the outer case  3 O and the middle case  3 M overlap with each other when mounted and receives the lower end of each side plate  3 Os and each circumference plate  3 Ms. An outer circumferential surface  3 Ia of the upper inner case  3 I is flush with each side plate  3 Os of the outer case  3 O. 
     A support portion  3 Is located within each circumference  3 Ms in the middle case  3 M is formed in the upper inner case  3 I in a state where the support portion  3 Is is mounted in the middle case  3 M. Moreover, the support portion  3 Is prevents each circumference plate  3 Ms from being curved. 
     In a case of mounting the above-described upper case  3 , the middle case  3 M is first intruded into the inner surface of the outer case  3 O, as shown in  FIG. 8(   a ), and then each engagement claw (engagement portion)  3 Mp of the middle case  3 M is engaged with each protrusion  3 Op of the outer case  3 O. 
     At this time, since the middle case  3 M is formed of a resin material, it is possible to easily engaging each engagement claw (engagement portion)  3 Mp with each protrusion  3 Op of the outer case  3 O by curving each circumference plate  3 Ms of the middle case  3 M. 
     Next, as shown in  FIG. 8(   b ), the outer case  3 O, the middle case  3 M, and the upper inner case  3 I are integrally mounted to each other by screw-fixing the upper inner case  3 I to the attachment boss (not shown) formed in the middle case  3 M. 
     At this time, the edge of the outer case  3 O is received in the stepped portion  3 Ir of the upper inner case  3 I so as not to be exposed outward. In addition, each side plate  3 Os of the outer case  3 O and the outer circumferential surface  3 Ia of the upper inner case  3 I form one smooth side surface. 
     In the state where the upper inner case  3 I is mounted, the support portion  3 Is formed in the upper inner case  3 I is positioned within each circumference plate  3 Ms of the middle case  3 M and suppresses the inward bending of each circumference plate  3 Ms. Accordingly, it is possible to prevent each engagement claw (engagement portion)  3 Mp from being detached from each protrusion  3 Op, thereby firmly mounting the upper inner case  3 I and the middle case  3 M to each other. 
     On the other hand, in a case where the upper case  3  is dissembled to perform a repair job, the upper inner case  3 I is first separated from the middle case  3 M, each engagement claw (engagement portion)  3 Mp of the middle case  3 M is detached from each protrusion  3 Op of the outer case  3 O, and then the middle case  3 M is separated from the inner surface of the outer case  3 O. 
     At this time, since the middle case  3 M is made of the resin material, it is possible to easily detach each engagement claw (engagement portion)  3 Mp from each protrusion  3 Op of the outer case  3 O by curving each circumference plate  3 Ms of the middle case  3 M. 
     In the cellular phone  1  having the above-described configuration, the lower border of each side plate  3 Os in the outer case  3 O of the upper case  3  is subjected to the inward bending process so that the edge of the metal plate is not exposed to the outside. Accordingly, it is possible to surely prevent the edge of the outer case  3 O from being exposed to the outside and from being damaged by a user. Therefore, since it is not necessary to additionally form a part of the case to cover the edge of the outer case  3 O, it is possible to improve a design. 
     Each protrusion  3 Op can be formed in the outer case  3 O by a simple process by forming each protrusion  3 Op of the outer case  3 O in L-shaped cross section with respect to each side  3 Os. Accordingly, rigidity of the outer case  3 O against an external force is improved by additionally subjecting the lower border of each side plate  3 Os of the outer case  3 O to the bending process. Therefore, it is possible to improve mechanical strength of the upper case  3  and the cellular phone  1 . 
     The lower border of each plate  3 Os of the outer case  3 O is processed so as be bent inward to form each protrusion  3 Op which protrudes in the inward direction of each side plate. Moreover, each engagement portion  3 Mp which engages with each protrusion  3 Op of the outer case  3 O is formed on each circumference plate  3 Ms of the middle case  3 M made of the resin material, and each protrusion  3 Op and each engagement portion  3 Mp engage with each other. In this way, the outer case  3 O and the middle case  3 M are integrally mounted to each other. Accordingly, it is possible to attach or detach the outer case  3 O and the middle case  3 M to or from each other by deforming each circumference plate  3 Ms of the middle case  3 M made of the resin material. As a result, the repair job can be easily performed. 
     The support portion  3 Is positioned within each circumference plate  3 Ms of the middle case  3 M is formed in the upper inner case  3 I mounted in the middle case  3 M, and the engagement of each protrusion  3 Op and each engagement portion  3 Mp is maintained by suppressing the bending of each circumference plate  3 Ms. Accordingly, it is possible to surely fix the middle case  3 M and the outer case  3 O so as not to be separated from each other in the state where the middle case  3 M is mounted in the upper inner case  3 I. 
       FIGS. 9 to 11  are diagrams illustrating a cellular phone according another embodiment of the invention. An upper case  3 ′ of the cellular phone  1 ′ includes an upper inner case (apparatus case)  3 I′ made of a magnesium alloy, for example, a middle case (middle member)  3 M′ formed of a resin material, and an outer case  3 O′ formed by a press molding process with a thin metal plate. 
     The outer case  3 O′ includes a front plate  3 Of′ and side plates  3 Os′ bent from the border portion of the front plate  3 Of′. The lower borders of the side plates  3 Os′ are subjected to a bending process so as to be inward formed in J-shaped cross section with respect to the side plates  3 Os′ so that the edge of the metal plate is not exposed outward. In addition, a protrusion  3 Op′ which protrudes in an inward direction of each side plate  3 Os′ is formed by each border subjected to the bending process. 
     The middle case  3 M′ includes a top plate  3 Mt′ corresponding to the front plate  3 Of′ of the outer case  3 O′ and circumference plates  3 Ms′ bent from the borders of the top plate  3 Mt′. An engagement claw (engagement portion)  3 Mp′ which engages with each protrusion  3 Op′ of the above-described outer case  3 O′ is formed on an outer surface of each circumference plate  3 Ms′. 
     In the upper inner case  3 I′, a stepped portion  3 Is′ for receiving each circumference plate  3 Ms′ of the middle case  3 M′ and a support portion  3 Ir′ positioned within each circumference plate  3 Ms′ are formed in a state where the upper inner case  3 I′ is mounted in the middle case  3 M′. An outer circumferential surface  3 Ia′ of the upper inner case  3 I′ is positioned in an inner surface of each side plate  3 Os′ of the outer case  3 O′. 
     That is, the outer circumferential surface  3 Ia′ of the upper inner case  3 I′ is covered with an side wall  3 Os′ of the outer case  3 O′. Accordingly, the entire outer circumferential surface of the upper case  3 ′ is constituted by the side walls  3 Os′ of the outer case  3 O′. 
     The configuration of the above-described cellular phone  1 ′ is the same that of the cellular phone  1  shown in  FIGS. 1 to 8  except for the shape of each side wall  3 Os′ including the protrusions  3 O′p of the above-described outer case  3 O′ and the shape of the stepped portion  3 Ir′ and each outer circumferential surface  3 Ia′ of the upper inner case  3 I′. The same reference numerals with addition of a prime mark thereafter are given to the operationally same elements shown in  FIGS. 1 to 8 , and the detailed description is omitted. 
     In the cellular phone  1 ′ having the above-described configuration, the entire outer circumferential surface of the upper case  3 ′ can be formed as each side wall  3 Os′ of the outer case  3 O′ by subjecting the lower border of each side wall  3 Os′ including the protrusion  3 Op′ of the outer case  3 O′ to the bending process to be bent inward so as to be formed in the sectional J shape. Accordingly, the design of the outer case  3 O′ made of metal can be sufficiently used. 
     Like the cellular phone  1  described above, in the cellular phone  1 ′ having the above-described configuration, it is possible to surely prevent user&#39;s damage caused due to the exposure of the edge of the outer case  3 O′ and to easily perform a repair job. Of course, additionally operational advantages can be obtained in that a mechanical strength of the cellular phone  1 ′ is improved, the outer case  3 O′ and the middle case  3 M′ can be surely fixed, and the like. 
       FIGS. 12 to 14  are diagrams illustrating a cellular phone according to other embodiment of the invention. A cellular phone  10  includes a lower case  12  forming a main body and an upper case  13  forming a cover body, which are connected to each other so as to be opened and closed, with a hinge member  14  interposed therebetween. 
     Illumination members  15  are provided in the right and left sides of the connection portion with the hinge member  14  in the end of the upper case  13 . The illumination members  15  covers an edge portion  13 Oe of the metal plate which is not subjected to the bending process in the outer case  13 O which constitutes the upper case  13 . 
     The illumination members  15  are attached to a holder portion  13 Mh of the middle case  13 M fixed to the inside of the outer case  13 O and perform illuminating by radiation of an LED (light source)  13  on a board  13   e  received in the upper case  13 . 
     The configuration of the above-described cellular phone  10  is the same that of the cellular phone  1 ′ shown in  FIGS. 9 to 11  except that the opening/closing mechanism of the lower case  12  and the upper case  13  is different, the pair of the right and left illumination members  15  are provided, and the shape of the middle case is difference because of the installation of the illumination members  15 . The 10s reference numerals made by adding 10s number without the prime mark from the reference numerals shown in  FIGS. 9 and 11  are given to the operationally same elements, and the detailed description is omitted. 
     In the cellular phone  10  having the above-described configuration, the illumination members  15  are provided to cover the edge portion  13 Oe formed of the metal plate in the region of the outer case  13 O which is not subjected to the bending process. With such a configuration, it is possible to surely prevent the user&#39;s damage caused by the exposure of the edge of the outer case  13 O without deterioration of the design. 
     In the cellular phone  10  having the above-described configuration, the middle case  13 M may be formed of a resin material having translucency, the illumination members  15  may be integrally formed with the middle case  13 M, illumination of the LED (light source)  13   o  may reach the illumination members  15  through the middle case  13 M. With such a configuration, it is possible to considerably reduce the number of the constitute elements. 
     Like the above-described cellular phone  1  and cellular phone  1 ′, in the cellular phone  10  having the above-described configuration, it is possible to improve the design, to surely prevent user&#39;s damage caused due to the exposure of the edge of the outer case  13 O′, and to easily perform the repair job. Of course, additionally operational advantages can be obtained in that a mechanical strength of the cellular phone  10  is improved, the outer case  13 O and the middle case  13 M can be surely fixed, and the like. 
     In the above-described embodiments, the invention is applied to the cellular phone which is just one example of electrical apparatuses. However, the invention is not limited to communication apparatuses such as a cellular phone or PHS (Personal Handyphone Systems) or portable information terminals such as an electronic dictionary or PDA (Personal Data Assistance), but may be effectively applied to various electronic apparatuses in which an outer case formed of a thin metal plate is mounted in an apparatus case, with a middle member formed of a resin material interposed therebetween. 
     As described with the reference to the embodiment, there is provided an electronic apparatus capable of preventing an edge of an outer case from being exposed and from being damaged by a user, and improving the design. 
     As described with the reference to another embodiment, there is provide the electronic apparatus capable of facilitating attachment or detachment of the outer case to or from a middle member in order to easily perform a repair job. 
     In the electronic apparatus according to an aspect, the lower borders of the side plates in the outer case are subjected to the bending process to be bent inward so that the edge of the metal plate is not exposed to the outside. With such a configuration, it is possible to surely prevent the edge of the outer case from being exposed and from being damaged by a user. Moreover, since it is not necessary to form a part of the case in order to cover the edge of the outer case, the design can be improved. 
     The lower borders of the side plates in the outer case are subjected to the bending process so as to be bent inward, the protrusions protruding inward are formed, the engagement portion for engaging the protrusions of the outer case are formed on the circumferential plates of the middle member formed of the resin material, and the outer case and the middle member are integrally formed with each other by engaging the protrusions to the engagement portions. With such a configuration, it is possible to facilitate the attachment or the detachment of the outer case to or from the middle member by deforming the circumferential plates of the middle member formed of the resin material. Accordingly, the repair job can be easily performed. 
     The support portions located inside the circumferential plates of the middle member are formed in the apparatus case mounted in the middle member. In addition, the support portions prevent the circumferential plates from being bent to maintain the engagement of the protrusions with the engagement portions. With such a configuration, the middle member and the outer case are not easily detached from each other in the state where the middle member is mounted in the apparatus case, thereby surely fixing them to each other. 
     The rigidity of the outer case against an external force can be improved by subjecting the lower borders of the side plates in the outer case. Moreover, it is possible to improve the strength of the electronic apparatus. 
     In the electronic apparatus according to another aspect, the protrusion of the outer case is formed in the sectional L shape with respect to the side plate. With such a configuration, it is possible to form the protrusion of the outer case by a simple process. 
     In the electronic apparatus according to another aspect, the protrusion of the outer case is formed in the sectional J shape with respect to the side plate. With such a configuration, it is possible to form the protrusion of the outer case by a simple process. 
     In the electronic apparatus according to another aspect, the illumination member which covers the edge of the metal plate is mounted in the area which is not subjected to the bending process in the outer case. With such a configuration, it is possible to surely prevent the edge of the outer case from being exposed and from being damaged by a user without deterioration of the design. 
     In the electronic apparatus according to another aspect, the middle member having translucency and the illumination member are integrally formed, such that illumination from the light source reaches the illumination member through the middle member.