Metal working – Method of mechanical manufacture – Combined manufacture including applying or shaping of fluent...
Reexamination Certificate
1998-09-18
2001-04-10
Hughes, S. Thomas (Department: 3726)
Metal working
Method of mechanical manufacture
Combined manufacture including applying or shaping of fluent...
C029S883000, C264S272150, C439S063000
Reexamination Certificate
active
06212755
ABSTRACT:
This application corresponds to Japanese Patent Application No. 9-255302, filed on Sep. 19, 1997, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing an insert-resin-molded product which is molded by means of integrating resin with a metallic member, and a product produced thereby.
2. Description of the Related Art
A description will be given of a conventional method for manufacturing an insert-resin-molded product, with reference to
FIGS. 4 through 6
. The described figures and method are not “prior art,” but “related art.”
As shown in
FIG. 4
, a chip-type connector
1
is formed as an insert-resin-molded product. The connector comprises an outer conductor
2
as a first metallic member, an inner conductor
3
as a second metallic member, and resin
4
which is molded by means of integrating resin with the metallic members.
First, the outer conductor
2
and the inner conductor
3
are prepared. The former, as shown in
FIG. 5
, is formed by a substantially pipe-shaped cylindrical portion
6
at the center thereof, a flange-like top surface portion
7
formed at one end of the substantially pipe-shaped cylindrical portion
6
, metallic parts
8
a
and
8
b
which are formed by bending the end portions of the top surface portion
7
in the direction of the substantially pipe-shaped cylindrical portion
6
, and legs
9
a
and
9
b
connected to the ends of the metallic parts
8
a
and
8
b. The metallic parts
8
a
and
8
b
have through-holes
10
a
and
10
b
disposed at approximately the respective centers thereof. The metallic parts
8
a
and
8
b
have shapes that substantially resemble the letter “U.” The through-holes
10
a
and
10
b
are made by cutting out two respective portions on the top surface portion
7
. A detailed description will be omitted of the inner conductor
3
shown in
FIG. 4
, as such a detailed description is unnecessary for the purpose of this disclosure.
Next, as shown in
FIG. 6
, there is prepared a resin-molding mold
32
, which has a cavity
31
capable of accommodating the outer conductor
2
and the inner conductor
3
. The cavity
31
is formed into a rectangular parallelepiped, at the center of which a protrusion
34
is disposed so as to be fitted into the inner periphery of the cylindrical portion
6
of the outer conductor
2
. Inner walls
33
of the cavity
31
are flat, except for the region of the protrusion
34
. The resin-molding mold
32
shown in
FIG. 6
forms a lower mold portion. An associated upper mold portion, which is not shown in
FIG. 6
, is equipped with a gate for injecting resin. The upper mold portion lays flat across and encloses the upper opening
35
of the cavity
31
.
Inside the cavity
31
of the resin-molding mold
32
, the outer conductor
2
and the inner conductor
3
are accommodated in a state in which these components remain insulated from each other. Molten resin
4
is injected into the cavity
31
of the resin-molding mold
32
after the upper opening
35
of the cavity
31
is enclosed by the upper mold portion. After the resin
4
injected into the cavity
31
has set, the whole device is taken out from the resin-molding mold
32
. A chip-type connector
1
is thereby obtained. More specifically, the device obtained is an insert-resin-molded product integrating the outer conductor
2
, the inner conductor
3
and the resin
4
into a unit, as shown in FIG.
4
.
As for surfaces of the chip-type connector
1
, referring to
FIG. 4
, a description will be provided using a side surface A of the device as an example. The end portions S
1
and S
3
and the center portion S
2
of the resin side surface, which are connected to the metallic part
8
a
, are formed flush with the surface of the metallic part
8
a
of the outer conductor
2
. The side surface A of the chip-type connector
1
is made flat in conformity with the configuration of the flat inner wall
33
of the cavity
31
, which corresponds to the side surface A, as shown in FIG.
6
.
In the above method for manufacturing the chip type connector
1
, however, when the mold is filled to excess with the molten resin
4
, the resin
4
may flow over the surface of the metallic part
8
a
, which is flush with the resin surfaces S
1
, S
2
and S
3
. As a result, the resin may be deposited on the surface of the metallic part
8
a
, resulting in the formation of “resin burrs”
5
.
Additionally, when a configuration of the corner portion R
1
of the bent metallic part
8
a
(shown in
FIG. 5
) differs from a configuration of the corresponding corner portion R
2
of the cavity
31
(shown in FIG.
6
), the resin
4
may flow over the surface of the corner portion of the metallic part
8
a
in a manner similar to that described above. Consequently, resin is deposited on the surface of the metallic part
8
a
, so that resin burrs
5
(Shown in
FIG. 4
) are generated.
SUMMARY OF THE INVENTION
The present invention has been made with a view toward solving at least the above-noted problems. Accordingly, it is an object of the present invention to provide a method for manufacturing an insert-resin-molded product, in which the generation of resin burrs on the surface of a metallic member caused by insert-resin-molding is prevented.
To this end, in accordance with the present invention, there is provided a method for manufacturing an insert-resin-molded product comprising the steps of: preparing a resin-molding mold having a cavity with an inner wall having a recess therein; preparing a metallic member to be placed in the cavity and to be integrally molded with resin, the metallic member having a metallic part which fits into the recess of the resin-molding mold; placing the metallic member in the cavity of the resin-molding mold and fitting the metallic part of the metallic member into the recess of the resin-molding mold; and, in this state, injecting resin into the cavity of the resin-molding mold to insert-resin-mold integrally with the metallic member.
Preferably, the recess of the resin-molding mold is formed in such a manner that the side surface of the recess is substantially perpendicular to the bottom surface of the same. This allows the flow of the molten resin to be substantially perpendicular to the side surface of the metallic member, so that the resin does not flow in the direction of the side surface of the metallic member, thereby, preventing resin burrs from being generated.
REFERENCES:
patent: 2937409 (1960-05-01), Cole
patent: 3978581 (1976-09-01), Michisita et al.
patent: 4556190 (1985-12-01), Smith
patent: 5078621 (1992-01-01), Nishikawa et al.
patent: 5336112 (1994-08-01), Michisita et al.
patent: 5525075 (1996-06-01), Michisita et al.
patent: 5724730 (1998-03-01), Tanaka
patent: 19620856A1 (1996-11-01), None
patent: 0 545 289A1 (1993-06-01), None
patent: 06190865 (1994-12-01), None
European Search Report dated Nov. 30, 1999.
Shimada Hiroaki
Takeuchi Shigeyuki
Yasojima Koji
Burns Doane , Swecker, Mathis LLP
Cozart Jermie E.
Hughes S. Thomas
Murata Manufacturing Co. Ltd.
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