Abstract:
A case of a portable equipment for communication to an external system comprises a body portion and an operation portion acting as a function member. At least a portion of the case is provided with a decorative film having a resin film having transparency and a print layer printed on a back surface of the resin film in a predetermined pattern, and a resin base member formed on a back surface of the decorative film so as to contact the print layer. The front surface of the decorative layer is exposed as a most outside surface of the case.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to a case for a portable equipment such as transmitter for key-less entry system of a vehicle. 
   There has been known a key-less entry system as a remotely controllable auxiliary means for a vehicle, which is provided with a portable equipment such as transmitter. The portable equipment is accommodated in a case having a case body generally colored with black. Further, in an event where color changing is effected to the case entirely or partially, the coloring is effected with resin or two-color formation. This coloring method has been considered to be undesirable in an impact in design, and especially, in the case of two-color formation, a fusing (fused) portion, at which the colors are different, provides a weak strength, thus being inconvenient. 
   Moreover, although as is well seen in a portable phone, for example, a UV coating of metallic color to a surface of the case has been considered, a portable equipment such as for keyless entry system is often engaged with a key holder or key ring together with keys formed of metal. In such case, there is a fear that the surface of the portable equipment may be injured by such metal keys and the durability of the portable equipment may be made worse. 
   Furthermore, in a case of a portable equipment of a type using an electric wave transmission, if the case body is coated with metallic material, the metallic coat film formed on the surface of the case body provides a considerably large thickness, and because of the metal contained in this coat film, permeability or transmission of the electric wave may be deteriorated thereby. 
   Furthermore, there is known a printing technology, in which a printing of an opaque, not transparent, ink is made on t transparent resin sheet. In such technology, when a light is projected, a pattern of the printing is made visible through the transparent sheet. There is known a coaster to which such printing technology is applied. 
   SUMMARY OF THE INVENTION 
   The present invention was conceived in consideration of the defects or inconveniences encountered in the prior art mentioned above and an object of the present is therefore to provide a case of a portable equipment having a surface capable of being decorated and being hard to be injured or damaged. 
   Another object of the present invention is to provide a case for a portable equipment having a surface coated with metallic color film having a high electric wave permeability. 
   These and other objects can be achieved according to the present invention by providing, in one aspect, a case of a portable equipment for communication to an external system comprising: 
   a body portion; and 
   an operation portion acting as a function member, 
   wherein at least a portion of the body portion and the operation portion is provided with: a decorative film having a resin film having transparency and a print layer printed on a back surf ace of the resin film in a predetermined pattern; and a base member resin portion formed on a back surface of the decorative film so as to contact the print layer, and the decorative layer has a front surface exposed as a most outside surface of the case. 
   According to the invention of this aspect, the decorative film having a transparent base film, to the back surface of which a printed layer having a predetermined print pattern is formed, is disposed to at least a portion of the case so that the front surface of the decorative film is disposed to the most outside surface portion of the case. According to this structure, the printed layer can be protected between the transparent film and the resin base member, so that the predetermined printed pattern of the printed layer can be free from external damage by, for example, a metallic key. 
   In addition, the case is applicable to another portable equipment having different function only by changing the pattern to be printed on the print layer. 
   In preferred embodiments of the above aspect, there are some advantageous features will be provided. 
   That is, a transparent protection film may be formed to the front surface of the resin film. In an arrangement in which this transparent protection film is disposed most outside the case, the transparency of the resin film can be preferably maintained. 
   The print layer may be formed of a material containing a metallic component to thereby provide a metallic feeling to the outside surface of the case through the transparent resin film. 
   The case body has an inner hollow structure in which an antenna element for transmission may be disposed. Since, in the present invention, the print layer has a thin thickness, the electric wave transmission is less reduced even though the print layer contains the metallic component, and thus, the lowering of the transmitting ability can be minimally suppressed. 
   The operation portion includes knob pieces for inputting operation modes and the knob pieces have front surfaces covered by the decorative film, thus being capable of protecting the knob member by the decorative film. 
   The print layer of the decorative film has a portion which covers the knob pieces and to which patterns representing contents of functions are printed. Therefore, the functions of the knob pieces can be easily recognized by a user. 
   The front surface of the decorative film may be provided with a marked or stamped portion formed as a protruded or recessed portion, which can enhance the touch feeling of a user. 
   The body portion and the operation portion may be covered integrally by the decorative film. According to this structure, the intrusion of water component or dust and the like into the case body can be prevented. The integral formation of the body portion and the operation portion of the case can contribute to cost reduction. 
   On the other hand, the body portion and the operation portion may be covered by independent decorative films, respectively. According to this structure, the decorative film may be formed for each of the operation portions having different functions. 
   The decorative film has an end portion intruding into the base member resin portion to thereby prevent the decorative film from being peeled off from the base member of the case. 
   The body portion may be formed from two half portions so as to have an inner hollow portion when assembled and the operation portion is formed to one of the two half portions. According to this structure, the case can be easily manufactured with a simple forming device. 
   In another aspect, the present invention provides a case of a portable equipment for communication to an external system comprising: 
   a body portion having an inner hollow structure in which an antenna element is disposed for communication to the external system; and 
   an operation portion acting as a function member having a surface on which knob pieces for inputting operation modes are formed, 
   wherein at least a portion of the body portion and the operation portion is provided with: a decorative film having a resin film having a front surface on which a transparent protection film is formed and a print layer printed on a back surface of the resin film in a predetermined pattern, the print layer containing a metallic component; and a base member resin portion formed on a back surface of the decorative film so as to contact the print layer, and the transparent protection film is disposed as a most outside surface of the case. 
   The nature and further characteristic features of the present invention will be made more clear from the following descriptions with reference to the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the accompanying drawings: 
       FIG. 1  is a longitudinal sectional view of a portable equipment as a key-less entry system according to one embodiment of the present invention; 
       FIG. 2  is a developed perspective view of the portable equipment of  FIG. 1 ; 
       FIG. 3  includes  FIG. 3A  being a plan view showing a decoration film effected to an upper cover of the portable equipment of  FIG. 1 ,  FIG. 3B  being a side or sectional view of  FIG. 1  and  FIG. 3C  being an enlarged sectional view of a portion of  FIG. 3B ; 
       FIG. 4  includes  FIG. 4A  being a plan view showing a decorative film applied to an upper cover of the portable equipment of  FIG. 3  after the forming working and  FIG. 4B  being a sectional view taken along the line IVB—IVB in  FIG. 4A ; 
       FIG. 5  includes  FIG. 5A  being a plan view showing an upper cover of the portable equipment of  FIG. 1  after the film in-mold formation,  FIG. 5B  being a sectional view taken along the line VB—VB in  FIG. 5A  and  FIG. 5C  being an enlarged sectional view of an end portion of the upper cover of  FIG. 5B ; 
       FIG. 6  is a plan view of a decorative film of a lower cover of the case of the portable equipment of  FIG. 1 ; 
       FIG. 7  includes  FIG. 7A  being a plan view showing a decorative film applied to the lower cover of the portable equipment of  FIG. 6  after the forming working and  FIG. 7B  being a sectional view taken along the line VIIB—VIIB in  FIG. 7A ; 
       FIG. 8  includes  FIG. 8A  being a plan view showing the lower cover of the portable equipment of  FIG. 1  after the film in-mold formation, and  FIG. 8B  being a sectional view taken along the line VIIIB—VIIIB in  FIG. 8A ; 
       FIG. 9  includes  FIGS. 9A and 9B  both showing a plan view of a decorative film of a knob member after the forming working of the embodiment of  FIG. 1 ; 
       FIG. 10  is a plan view of a decorative film of an upper cover of a case of a portable equipment according to another embodiment of the present invention; 
       FIG. 11  includes  FIG. 11A  being a plan view showing a decorative film effected to the upper cover of the portable equipment of according to the embodiment of  FIG. 10  after the forming working and  FIG. 11B  being a sectional view taken along the line XIB—XIB in  FIG. 11A ; and 
       FIG. 12  includes  FIG. 12A  being a plan view showing the upper cover of the portable equipment of  FIG. 10  after the film in-mold formation,  FIG. 12B  being a sectional view taken along the line XIIB—XIIB in  FIG. 12A  and  FIG. 12C  being a sectional view taken along the line XIIB—XIIB in  FIG. 12A  in which a knob printing portion is flexed in shape of recess. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Preferred embodiments of the present invention will be described hereunder with reference to the accompanying drawings. It is to be noted that, in the following descriptions, terms of “upper”, “lower” and the like are used with reference to the illustrated state. 
   First Embodiment 
   The first embodiment of the present invention will be first described with reference to  FIGS. 1 and 2 . 
   A portable equipment  1  comprises upper and lower case covers  2  and  9  which constitute an outer case and elements disposed in an inner space defined by the upper and lower case covers  8  and  9  when assembled into the case. As best illustrated in  FIG. 2 , the elements include: a knob member  3 ; a water-proof cover  4 ; a circuit board  5  provided with switching elements  51   a  to  51   c  on its upper surface and an antenna element  6  on its lower surface; a cushion member  7  disposed between the antenna element  6  and the lower case cover  9  for damping a shock to the antenna element  6 ; a cell terminal  81 ; a cell case  82 ; a button cell  83 ; and a spacer  80  supporting the circuit board  5  from the lower case cover  9 , in substantially the described order. Further, other circuit elements disposed on the lower surface of the circuit board are omitted from the illustration in  FIG. 1 . 
   Referring to  FIG. 2 , the knob member  3  includes knob pieces  31   a ,  31   b  and  31   c  each formed in shape of protrusion from a decorative film  100 , which will be mentioned hereinlater in detail, and the switching elements  51   a ,  51   b  and  51   c  formed on the upper surface of the circuit board  5  are arranged below the respective knob pieces  31   a ,  31   b  and  31   c  through the water-proof cover  4  made of silicone resin. Further., the knob piece  31   c  is provided, at its upper surface, with a projection piece  32  so as to be easily distinctive from the other knob pieces  31   a  and  31   b.    
   Hereunder, with reference to  FIGS. 1 to 9 , the formation method of the upper case cover  2 , the lower case cover  9  and the knob member  3  with the decorative film  100  will be described. 
   As shown in  FIG. 3  ( FIGS. 3A to 3C ), the decorative film  100  is made of polycarbonate PC, having light transmittancy, and has thickness t of 0.3 mm (t=0.03 mm). More specifically, the front surface of the transparent resin film  101  (corresponding to the most outside surface of the portable equipment  1 ) is entirely coated with a transparent protective film  102  of hard-coat agent, and a print (printed or printing) layer  103  is formed on the rear (back) surface of the resin film  101  (corresponding to a surface of the upper case cover  2  contacting a base member BP formed of resin for the upper case cover  2 ). 
   The print layer  103  comprises two-color printing portions including a metallic printing portion  110  formed of an ink containing metallic component such as aluminium powder and a body color printing portion  120  formed of an ink having a body case color (black in this embodiment). These metallic printing portion  110  and body color portion  120  constitute a body portion of the upper case cover  2 . 
   The metallic printing portion  110  is formed with an LED (light emitting diode) portion  111  on which any printing is not applied in order to transmit the emitting light of the LED, not shown, indicating an operation mode of the portable equipment  1 . On the other hand, the body color printing portion  120  is formed with holes  21   a  to  21   c , for the knob member  3  as function (operation) member, corresponding to non-printed portions  121   a  to  121   c  and a non-printed portion  121   d  corresponding to a keeling hole  20 . 
   Incidentally, in order to provide a metallic feeling to the case body, it is generally required to apply the coating so that the coated film provides a thickness of about 30 μm, and in such coated film, the metallic component is contained, which adversely affects on the transmission performance of the electric wave, thus being inconvenient. 
   On the contrary, in the printed layer  103  of the described embodiment of the present invention, the metallic color printing portion  110  and the body color printing portion  120  each merely has a thickness of about 3 μm. Accordingly, the metallic feeling can be provided by the less amount of the metallic component of the metallic printing portion  110  and, in addition, an adverse influence on the electric wave transmission performance of the antenna element  6  in the portable equipment  1  can be minimally suppressed. 
   In the next step, the decorative film  100  shown in  FIG. 3A  is subjected to a forming working by using a die, not shown. Further,  FIG. 4A  shows a plan view of the decorative film  100  after the forming working. 
   In the forming working, an end portion of the decorative film  100  is cut, and a three-dimensional formation along the surface shape of the upper case cover  2  is performed. The forming of the knob holes  21   a  to  21   c  and the keeling hole  20  are also performed. In the three-dimensional formation of the decorative film  100 , the projection  32  to the knob piece  31   c  will be also formed. 
   The decorative film  100  subjected to the forming working is set to a molding machine, not shown. Then, the resin base member formed of polycarbonate (PC) is injected on the side of the printing layer  103  by the film in-mold method to thereby form the upper case cover  2 . 
     FIG. 5A  shows a plan view of the upper cover  2  formed by this film in-mold method,  FIG. 5B  is a sectional view taken along the line VB—VB in  FIG. 5A  and  FIG. 5C  is an enlarged sectional view showing an end portion M of the decorative film  100 . 
   At the time of the in-mold formation, the resin material for the base member BP moves and turns so as to catch the end portion M of the decorative film  100  in a manner that this end portion M enters into the base member BP. Hence, the end portion M of the decorative film  100  is not exposed externally, so that the decorative film  100  can be prevented from being peeled off from the resin base member BP. 
   Furthermore, the material of the resin film  100  of the decorative film  100  is the same as the material of the resin base member BP, that is, both being formed of PC (polycarbonate). Accordingly, both the materials have the same linear expansion coefficient, so that both the resin film  101  of the decorative film  100  is not peeled off from the resin base member BP after the in-mold formation. 
   The lower case cover  9  of the portable equipment  1  according to the described first embodiment will be manufactured substantially the same manner or steps as those mentioned above with reference to the upper case cover  2 . 
   Referring to  FIGS. 6 to 8 , reference numeral  200  denotes a decorative film of the lower case cover  9 . A resin film  201  is formed of a polycarbonate resin and has a front surface on which a transparent protective film  102  of hard-coat agent is formed and a back (rear) surface on which a black body color printing portion  220  is formed. The resin film  201  is then subjected to the forming working for cutting the end portion, forming the keeling hole and carrying the three-dimensional molding. The formed decorative film  210  is molded through the in-mold process with the polycarbonate resin base member BP to thereby form the lower case cover  9 . 
   Further, a mark, not shown, showing a maker, a kind of car, or like may be formed on the surface of the lower case cover  9  of the portable equipment  1  by forming, through for example stamping process, protrusion or recess on the surface of the decorative film  210  at the time of forming working. 
   On the other hand, as to the knob member  3 , decorative films  310 ,  320  decorated for the knob member (knob pieces) is formed through the forming working substantially identical to that for the decorative film  100  or  200 . 
   With reference to  FIG. 9 ,  FIG. 9A  shows one example of the knob member of a portable equipment for a one-box car, in which patterns respectively showing the knob piece  31   c  for a door-lock switch, the knob piece  31   b  for a door-unlock switch and the knob piece  31   a  for a slide-door opening switch are multi-color printed, as switch pattern print portions, on the back surface of the decorative film  310 . 
   On the other hand,  FIG. 9B  shows one example of the knob member of a portable equipment for a sedan-type vehicle, in which a pattern showing a knob piece  311   a  for a trunk-unlock switch is multi-color printed on the back surface of a decorative film  320  in place of the slide-door opening switch. 
   Thus, according to the first embodiment of the present invention, it is possible to manufacture or provide a case of the potable equipment capable of being utilized for cars of different types or kinds, or different functions merely by changing the print (printing or printed) pattern. 
   Further, since the back surface of the knob member  3  contacts the switches  51   a  to  51   c  through the water-proof cover  4  at the switching time, it may be desired to apply the hard-coat agent on the surface of the printed layer  103  of the knob member  3  so as to protect the layer  103 . 
   As mentioned hereinabove, according to the first embodiment of the present invention, the upper case cover  2 , the lower case cover  9  and the knob member  3  can be formed by utilizing or using the decorative films  100 ,  200 ,  310 ,  320 , which are subjected to the three-dimensional molding. Each of these decorative films is formed from the transparent polycarbonate resin film  101  which has the front surface on which the transparent protective film of the hard-coat agent is formed and has the back surface on which the printed layer  103  provided with the metallic print portion  110  ( 210 ) and the body color print portion  120  ( 220 ) or switch pattern printed portion  31   a  ( 31   b ,  31   c ,  311   a ) are formed. Thereafter, the upper and lower case covers  2  and  9  are formed by the film in-mold method, i.e., injection-molding the resin BP for the base member on the printed layer side of the back (rear) surface of the decorative film  100  ( 200 ) which has been subjected to the forming working. 
   Accordingly, the transparent protective film  102  as the surface of the decorative film  100  ( 200 ) is exposed on the most outside surface of the portable equipment. Moreover, since the printed layer  103  is sandwiched between the resin film  101  and the resin base member BP on the back surface of the decorative film  100  ( 200 ), it becomes possible to prevent the printed layer  103  from being damaged by a metallic member such as key of an automobile, and in addition, the printed layer  103  can be seen from the outside of the portable equipment case through the transparent protective film  102  and the transparent resin film  101 . 
   Still furthermore, it is possible to make thin the thickness of the printed layer  103  containing the metallic component of an amount leas than the coat film thickness, so that the metallic feeling can be given to the case of the portable equipment  1  by the formation of the metallic printed portion  110  ( 210 ), and in addition, an adverse influence to the electric wave transmission performance of the antenna element  6  disposed inside the portable equipment  1  can be made minimal. 
   Thus, according to the first embodiment of the present invention, there can be provided a portable equipment case decorated by the metallic color coat and body color coat having good durability and having less influence to the electric wave transmission performance of the integrated antenna element. 
   Second Embodiment 
   In the first embodiment mentioned above, the upper case cover  2  and the lower case cover  9  are formed as independent members, whereas in this second embodiment, both the case covers are formed integrally, and this second embodiment differs from the first embodiment in a structure that two switch knobs are integrally formed to the upper case cover  2 . According to this viewpoint, only the upper case cover  2  is explained hereunder through its manufacturing process with reference to  FIGS. 10 to 12 . 
     FIG. 10  is a plan view of a decorative film  400  according to this second embodiment, in which the resin film  101  made of polycarbonate (PC) and having a thickness t=0.3 mm and the transparent protection film  102  made of UV hard coat agent are the same as those in the first embodiment. 
   The print (printed or printing) layer  103  includes, as like as in the first embodiment, an metallic printed portion  410 , as a body portion, of ink including metallic component and a body color print portion  420  printed with black color and also is provided with knob printed portions  421   b ,  421   c  printed with brown as a control (function or operation) portion. As like as the first embodiment, the metallic printed portion  410  includes an LED portion  411 , at which no printing is made, and the body color printed portion  420  is formed with a non-printed portion  421   d  for a keeling hole. 
   The thus formed decorative film  400  is subjected to a forming working by means of die, not shown, as like as the first embodiment.  FIG. 11A  is a plan view of the decorative film  400  after the forming working and  FIG. 11B  is a sectional view thereof taken along the line XIB—XIB. 
   As shown in  FIG. 11B , in the forming working in this second embodiment, the keeling hole  20  is formed and the knob printed portions  421   b ,  421   c  are formed in shape of protrusion without being formed as a hole or like. Moreover, a projection  432  is formed to the surface of the knob printed portion  421   c  for knob discrimination. 
   The decorative film  400  after the forming working is set to a molding machine, not shown, as like as the first embodiment, and subjected to the injection molding by the film in-mold method so as to inject the base material resin (i.e. resin base member) BP of polycarbonate to the side of the printed layer  103 . Further,  FIG. 12A  is a plan view of the upper case cover  2  formed by the film in-mold method, and with reference to  FIG. 12C , it will be seen that the knob printed portions  421   b  and  421   c  are deformable in a concave shape (recess) by a force of operating the knobs. 
   According to the portable equipment case according to the second embodiment of the present invention, as like as the first embodiment, the transparent protection film  102  as the front surface of the protective film  400  is exposed to the most outside surface of the case of the portable equipment  1 , and the printed layer  103  is sandwiched, on the rear surface of the decorative film  400 , between the resin film  101  and the base material resin BP. Accordingly, the surface of the printed layer  103  can be prevented from being damaged by a metallic article, and on the other hand, the printed layer  103  can be observed from the outside thereof through the transparent protection film  102  and the transparent resin film  101 . 
   In addition, the thickness of the metallic layer  103  containing the metallic component can be made thin even in comparison with a coat film. Therefore, the metallic feeling can be given to the case of the portable equipment  1  by the metallic printed portions  410  and  210 , and moreover, an adverse influence to be given to the electric wave performance of the antenna element  6  disposed inside the portable equipment  1  can be made minimal. 
   Still furthermore, in the second embodiment of the present invention, the knob printed portions  421   b  and  421   c  as function portions covering the switches  51   b  and  51   c  of the circuit board  5  are formed integrally with the decorative film  400  forming the body color printed portion  420  and the metallic printed portion  410 . Accordingly, there exists substantially no gap between the function portion and the body portion of the case surface, thus improving the water-proof ability, dust-proof ability and the like to the case of the portable equipment. 
   Other Embodiments 
   Further, it is to be noted that the present invention is not limited to the described embodiments and many other changes and modifications may be made without departing from the scopes of the appended claims. 
   For example, in the described embodiments, the transparent polycarbonate (PC) film is utilized for the resin film  101  as the base of the decorative film. In an alternation, however, a transparent polyetylenetelephthalate (PET) may be used. Further, the resin film thickness may be selected in a range of 0.18 to 0.5 mm to thereby easily form or mold the decorative film at the forming working. 
   In addition, there is also used, for the resin film  101 , a translucent film other than the transparent one to obtain mette metallic feeling. 
   As the resin base member or base material resin BP, there may be utilized, other than the PC, a mixture resin of the PC and ABS resin. In such case, it is desired, in order to enhance the moldability in the film in-mold process, that the linear expansion coefficients of the resin film and the base material resin BP of the decorative film accord or substantially accord with each other.