Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No(s). 201310239723.2 filed in China, P.R.C. on Jun. 17, 2013, the entire contents of which are hereby incorporated by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field of the Invention 
         [0003]    The disclosure relates to a case structure for an electronic device and manufacturing method thereof, more particularly to a case structure for an electronic device formed by injection molding and the manufacturing method thereof 
         [0004]    2. Description of the Related Art 
         [0005]    As technology advances and high-tech industries develop, the market competition for electronic devices (e.g., laptops, mobile phones, tablets, electronic dictionaries or portable game consoles) is more intense. In order to satisfy the customers&#39; requirements for the performance of the electronic devices, in related industries invest a large amount of money on the research and development for improving the performance of the electronic devices. As a result, the performance of the electronic devices improves incessantly. 
         [0006]    Since the performance of the electronic devices has been improved, the heat generated by the electronic devices has increased. In order to eliminate the heat from the electronic devices, the aluminum foil and the graphite sheet are usually attached on the case made by plastic, so as to perform the heat dissipation. However, this approach requires additional working which increases the cost in the production line. Furthermore, since the shapes of the cases vary, the aluminum foil and the graphite sheet cannot be attached to the case evenly, and this affects the heat dissipation result negatively. Hence, how to manufacture a case without the additional processing of the aluminum foil and the graphite sheet is a problem needed to be solved by the related industries. 
       SUMMARY OF THE INVENTION 
       [0007]    A method for a case for an electronic device is disclosed. In the method, a first plastic layer is formed by injection molding. A PCM (phase change material microcapsule) layer is formed on one side of the first plastic layer. 
         [0008]    The disclosure further provides a case structure for an electronic device comprising a first plastic layer and a PCM microcapsule layer. The PCM microcapsule layer is disposed on one side of the first plastic layer. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The present disclosure will become more fully understood from the detailed description given herein below for illustration only, and thus does not limit the present disclosure, wherein: 
           [0010]      FIG. 1  is a flow chart of a method for forming a case for an electronic device according to the first embodiment of the disclosure; 
           [0011]      FIG. 2  is a schematic view of forming the first plastic layer in the method according to the first embodiment of the disclosure; 
           [0012]      FIG. 3  is a schematic view of forming the PCM (phase change material) microcapsule layer in the method according to the first embodiment of the disclosure; 
           [0013]      FIG. 4  is the front view of the structure of the PCM microcapsule according to the first embodiment of the disclosure. 
           [0014]      FIG. 5  is the front view of the case structure for the electronic device according to the first embodiment of the disclosure; 
           [0015]      FIG. 6  is a flow chart of a method for forming a case for an electronic device according to the second embodiment of the disclosure; 
           [0016]      FIG. 7  is a schematic view of forming the second plastic layer in the method according to the second embodiment of the disclosure; and 
           [0017]      FIG. 8  is the front view of the case structure for the electronic device according to the second embodiment of the disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing. 
         [0019]    Referring to  FIG. 1  to  FIG. 4 ,  FIG. 1  is a flow chart of a method for forming a case for an electronic device according to the first embodiment of the disclosure;  FIG. 2  is a schematic view of forming the first plastic layer in the method according to the first embodiment of the disclosure;  FIG. 3  is a schematic view of forming the PCM (phase change material) microcapsule layer in the method according to the first embodiment of the disclosure;  FIG. 4  is the front view of the structure of the PCM microcapsule according to the first embodiment of the disclosure. 
         [0020]    The first embodiment of the disclosure provides a method for forming a case for an electronic device. The method comprises: 
         [0021]    S 1 : Forming a first plastic layer by injection molding. Specifically, as shown in  FIG. 2 , the injection molding machine  10  makes the first plastic material  14  become the first plastic layer  161  and forms the first plastic layer  161  in the mold  15  by injection molding. In this embodiment, the material of the first plastic layer  161  (the first plastic material  14 ) is a mixture of polycarbonate and ABS resin, but the disclosure is not limited thereto. 
         [0022]    S 2 : Forming a PCM microcapsule layer on one side of the first plastic layer by injection molding. Specifically, as shown in  FIG. 3  and  FIG. 4 , the injection molding machine  10  makes a plurality of PCM microcapsules  20  become the PCM microcapsule layer  163  and forms the PCM microcapsule layer  163  on one side of the first plastic layer  161 . In this embodiment, the PCM microcapsule layer  163  comprises a plurality of PCM microcapsules  20 . The PCM microcapsules  20  each comprises a capsule shell  22  and a capsule core  24 . The capsule core  24  is located inside the capsule shell  22 . Preferably, the capsule core  24  is enclosed by the capsule shell  22 . The material of the capsule shell  22  is a high polymer, and the material of the capsule core  24  is a PCM. The melting point of the PCM is between 20° C. and 75° C., preferably between 35° C. and 55° C. In this embodiment, the high polymer forming the case shell  22  is a mixture of polycarbonate and glass fiber. The PCM forming the case core  24  is a heat absorbing substance, such as alkanes (e.g. icosane to triacontane), alcohols (e.g. decan-1-ol to icosane-1-ol), acids (e.g. decanoic acid to icosanoic acid) or paraffin. However, the material and the composition of the capsule shell  22  and the capsule core  24  are not limited to the disclosure. In this embodiment, the diameter of the PCM microcapsules is between 0.1 and 1000 micrometers (μm), preferably between 10 and 30 micrometers, and more preferably between 20 and 30 micrometers. Since the first plastic material  14  is a mixture of polycarbonate and ABS resin, and the melting of the mixture of polycarbonate and ABS resin is about 230° C. By comparison, the melting point the mixture of polycarbonate and glass fiber which forms the capsule shell  22  is about 285° C. In other words, the melting point of the capsule shell  22  is higher than the melting point of the first plastic material  14 . Consequently, when the PCM microcapsules  20  is undergone the injection molding process after the first plastic layer  161 , the temperature, set for the first plastic layer  161  for the injection molding, of the injection molding machine  10  is lower than the melting point of the capsule shell  22 . Thereby, structural integrity of the PCM microcapsules  20  can be maintained. 
         [0023]    Moreover, the disclosure provides a case structure for the electronic device. Referring to  FIG. 4  and  FIG. 5 ,  FIG. 5  is the front view of the case structure for the electronic device according to the first embodiment of the disclosure. 
         [0024]    After the injection molding machine  10  forms the PCM microcapsule layer  163  on one side of the first plastic layer  161 , the users may remove the case structure  16  for the electronic device from the mold  15 . The case structure  16  for the electronic device comprises a first plastic layer  161  and a PCM microcapsule layer  163 . The PCM microcapsule layer  163  is disposed on one side of the first plastic layer  161 . 
         [0025]    In the case structure for the electronic device and the manufacturing method thereof according to the first embodiment of the disclosure, the PCM microcapsule layer  163  is disposed on one side of the first plastic layer  161 , and the PCM has a great latent heat. That is, the PCM is capable of absorbing a large amount of heat when phase is changing. Therefore, the heat dissipation performance of the case structure  16  for the electronic device is improved, and this approach does not require attaching the aluminum foil and the graphite sheet on the surface of the case. Thereby, the additional working cost caused by attaching the aluminum foil and the graphite sheet to the case surface, as mentioned in the related art, is eliminated. 
         [0026]    The second embodiment of the disclosure provides a manufacturing method for a case structure for an electronic device. Referring to  FIG. 2 ,  FIG. 3 ,  FIG. 6  and  FIG. 7 ,  FIG. 6  is a flow chart of a method for forming a case for an electronic device according to the second embodiment of the disclosure;  FIG. 7  is a schematic view of forming the second plastic layer in the method according to the second embodiment of the disclosure. 
         [0027]    The manufacturing method for the case structure for the electronic device according to the second embodiment is similar to that in the first embodiment, wherein the difference is that a step S 3  is added after  FIG. 3 . The Step S 3  comprises: forming a second plastic layer on one side of the PCM microcapsule layer by injection molding, wherein the first plastic layer and the second plastic layer surround the PCM microcapsule layer. In this embodiment, the material of the second plastic layer is a mixture of polycarbonate and ABS resin, but the disclosure is not limited thereto. 
         [0028]    Specifically, as shown in  FIG. 7 , the injection molding machine  10  make the second plastic material  26  become the second plastic player  365  and forms the second plastic player  365  on one side of the PCM microcapsule layer  363 . The first plastic player  361  and the second plastic player  365  surround the PCM microcapsule layer  363 . 
         [0029]    Moreover, the second embodiment of the disclosure provides a case structure for the electronic device. Referring to  FIG. 8 ,  FIG. 8  is the front view of the case structure for the electronic device according to the second embodiment of the disclosure. 
         [0030]    After the injection molding machine  10  forms the second plastic layer  26  on one side of the PCM microcapsule layer  363 , the users may remove the case structure  30  for the electronic device from the mold  15 . The case structure  30  for the electronic device comprises a first plastic layer  361 , a second plastic layer  365  and a PCM microcapsule layer  363 . The first plastic layer  361  and the second plastic layer  365  surround the PCM microcapsule layer  363 . 
         [0031]    In the case structure for the electronic device and the manufacturing method thereof according to the second embodiment of the disclosure, since the case structure  30  for the electronic device comprises the PCM microcapsule layer  363 , and the PCM has a great latent heat. That is, the PCM is capable of absorbing a large amount of heat when phase is changing. Therefore, the heat dissipation performance of the case structure  30  for the electronic device is improved, and this approach does not require attaching the aluminum foil and the graphite sheet on the surface of the case. Thereby, the additional working cost caused by attaching the aluminum foil and the graphite sheet to the case surface, as mentioned in the related art, is eliminated. 
         [0032]    In the case structure for the electronic device and the manufacturing method thereof according to the above-mentioned embodiments, since the case structure for the electronic device comprises the PCM microcapsule layer, the heat dissipation performance can be improved. Furthermore, this approach does not require attaching the aluminum foil and the graphite sheet to the case surface. Thereby, the additional working cost of attaching the aluminum foil and the graphite sheet can be eliminated. 
         [0033]    It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.

Technology Category: b