Display device

Abstract

A display device is provided with: a display module including a display configured to display an image; and a resin case holding the display module, the resin case including: an outer side portion having an outer side surface facing an outer side of the resin case; and an inner side portion having an inner side surface facing an inner side of the resin case, the inner side portion having a gate forming portion having a first surface and a second surface facing away from the first surface, the second surface of the gate forming portion is provided spaced apart from the outer side surface via a space portion of the resin case, the inner side portion has a rib portion extending from the inner side surface and connected to the gate forming portion, and the rib portion has an opening forming the space portion of the resin case.

Description

[0001] This application is a divisional application of the invention entitled “Manufacturing method and display device of resin molded product” and application number 201980041251.5, filed on June 17, 2019.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of Japanese Patent Application No. 2020-135274 filed on August 7, 2020. The entire disclosure of Japanese Patent Application No. 2020-135274 is hereby incorporated by reference herein. Technical Field

[0004] The present invention generally relates to a display device. Background Art

[0005] A method for producing a resin molded article includes the step of forming the resin molded article (for example, refer to Japanese Patent Application Laid-Open No. 2011-240508 (Patent Document 1)).

[0006] The above-mentioned patent document 1 discloses a casing manufacturing method for a thin display device (a method for manufacturing a resin molded product), which includes the step of forming a front casing (resin molded product). The above-mentioned step of forming the front casing includes forming a cavity corresponding to the front casing between a fixed side mold and a movable side mold. Here, the fixed side mold and the movable side mold face each other in the movable direction of the movable side mold. In addition, the outer side of the product is arranged on the movable side mold. The outer side of the product is the surface of the movable side mold that forms the outer side surface of the front casing.

[0007] The housing manufacturing method of Patent Document 1 includes a step of filling the cavity with resin by directly injecting the resin into the cavity from a resin injection port of a hot runner (hot sprue). Here, the fixed side mold is provided with a resin injection port at a position facing the outer side of the product.

[0008] However, with the casing manufacturing method of Patent Document 1, the resin ejected from the hot runner directly hits the outer side of the product of the opposite movable side mold (i.e., the portion corresponding to the outer side of the product). In this case, the resin ejected from the hot runner and hitting the outer side of the product (i.e., the portion corresponding to the outer side of the product) may rebound, which may cause outer defects around the portion of the outer side of the product hit by the resin. When this happens, the problem with the casing manufacturing method of Patent Document 1 is that unless the molding conditions are changed, such as reducing the injection (injection) speed of the resin ejected from the hot runner or expanding the cavity space, the outer defects cannot be reduced. In addition, if the molding conditions are changed, it will place a heavy burden on the operator to change the molding conditions and set the optimal molding conditions.

[0009] Here, the following is considered as the cause of the outer defects around the part of the outer side of the product hit by the resin. That is, the resin cannot be effectively filled around the part of the outer side of the product hit by the resin due to the resin rebound, and the density of the resin in the cavity may be uneven. Because the density of the resin in the cavity is uneven, the outer side surface of the product turns white due to the difference in the shrinkage of the resin, or the outer defects that match the rebound flow of the resin are generated on the outer side of the product may occur. Summary of the invention

[0010] An object is to provide a display device capable of reducing outer defects without changing molding conditions.

[0011] (1) In view of the state of the known art and according to a first aspect of the present invention, a method for manufacturing a resin molded product includes: forming a cavity having a shape corresponding to the resin molded product by bringing a plurality of resin molding dies into abutment with each other; and forming the resin molded product by directly injecting resin from a resin injection port to a resin injection gate (resin injection gate) and filling the cavity with the resin. The forming of the resin molded product includes filling the cavity with the resin while changing the flow of the resin directly from the resin injection gate toward the cavity by a resin flow changing portion (resin flow changing portion) provided opposite to the resin injection gate.

[0012] For the manufacturing method of the resin molded product according to the first aspect, the formation of the resin molded product is arranged to fill the cavity with resin while changing the resin flow directly from the resin injection gate toward the cavity by a resin flow changing portion arranged opposite to the resin injection gate. Therefore, the resin ejected from the resin injection port hits the opposite resin flow changing portion that changes the resin flow. Therefore, when the resin ejected from the resin injection port reaches the outer side surface, the resin will have a smaller momentum than the case where the ejected resin directly reaches the outer side surface, so that the rebound of the resin in the cavity can be reduced. Therefore, the unevenness of the resin density in the cavity can be reduced while filling the cavity with resin, so that the outer side defects such as whitening of the outer side surface due to the difference in shrinkage of the resin and the generation of a pattern on the outer side surface of the product that matches the rebound flow of the resin are reduced. As a result, the outer side defects can be reduced by the resin flow changing portion without changing the molding conditions.

[0013] (2) Based on a preferred embodiment of the method for manufacturing a resin molded product according to the above, filling the cavity with resin includes branching the resin flow injected from the resin injection gate by the resin flow changing portion. According to this structure, the amount of resin can be dispersed by branching the resin flow, so the kinetic energy of each branched resin flow can be reduced compared to the original resin flow. As a result, the momentum of each branched resin flow can be reduced compared to the original resin flow, so the rebound of the resin in the cavity can be further suppressed.

[0014] (3) Based on a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, filling the cavity with resin includes causing the resin flow injected from the resin injection gate to branch in two or more directions that intersect (intersect) with the resin injection direction of the resin injected from the resin injection gate through a resin flow changing portion. According to this structure, each time the branching of the resin flow increases, the amount of resin can be dispersed by the increased amount of branching of the resin flow. Therefore, by increasing the amount of branching of the resin flow, the kinetic energy of each branched resin flow can be further reduced compared to the original resin flow. As a result, the momentum of each branched resin flow can be further reduced compared to the original resin flow, thereby further suppressing the rebound of the resin in the cavity.

[0015] (4) Based on a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, the formation of the cavity includes making a movable mold provided with an outer side surface forming portion configured to form the outer side surface of the resin molded product, a sliding mold provided with a resin flow changing portion, and a fixed mold abut against each other, and the branching of the resin flow includes changing the resin flow injected from the resin injection gate by the resin flow changing portion of the sliding mold, thereby branching the resin flow. According to this structure, the resin flow changing portion is provided in the sliding mold separated from the fixed mold and the movable mold. Therefore, when the resin molded product is separated from the mold, the sliding mold can slide to remove (take off) the resin flow changing portion from the resin molded product, and therefore, the resin molded product can be easily separated from the mold without being stuck by the resin flow changing portion.

[0016] (5) According to a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, the formation of the resin molded product includes: injecting resin from a resin injection gate; and forming a gate forming portion as a non-outer portion provided inside the resin molded product between the resin flow changing portion and the resin injection gate by directing the resin flow toward the resin flow changing portion. According to this structure, even if rebound occurs in the gate forming portion, since the gate forming portion is the non-outer portion, the resin molded product will not have an outer defect, and thus the outer side of the resin molded product can be kept good.

[0017] (6) Based on a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, filling the cavity with resin further includes: in a case where the sliding mold is attached to the movable mold and the fixed mold, and the resin flow changing portion of the sliding mold in a direction perpendicular to the resin injection direction of the resin has a width greater than the width of the gate forming portion, filling the cavity with resin while changing the resin flow directly toward the cavity from the resin injection gate by the resin flow changing portion. According to this structure, the branched resin flow toward the outer side surface forming portion can be diverted by the width of the resin flow changing portion, and thus the momentum of the branched resin flow can be further reduced.

[0018] (7) Based on a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, filling the cavity with resin further includes: when the sliding mold is attached to the movable mold and the fixed mold, and the resin flow changing portion of the sliding mold has a height higher than the height of the gate forming portion in the resin injection direction of the resin, the cavity is filled with resin while changing the resin flow directly from the resin injection gate toward the cavity by the resin flow changing portion. According to this structure, the length of the flow path of the branched resin toward the outer side surface forming portion can be increased by the height of the resin flow changing portion, and thus the momentum of the branched resin flow can be further reduced.

[0019] (8) Based on a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, filling the cavity with resin further includes: branching the resin toward one side of a specific direction along a rib portion formed as a non-outer portion and extending in the specific direction and toward the other side of a direction opposite to the specific direction by a resin flow changing portion. According to this structure, the rib portion can be used to branch the resin flow, and therefore, the structure of the resin molding mold can be simpler than when a dedicated structure for branching the resin flow is provided.

[0020] (9) Based on a preferred embodiment of the method for manufacturing any of the above-mentioned resin molded products, the forming of the resin molded product includes forming a housing of a display device as the resin molded product. According to this structure, the housing of the display device with fewer external defects can be obtained without changing the molding conditions by the resin flow changing portion.

[0021] (10) In view of the known technology and according to the second aspect of the present invention, a display device comprises: a display module including a display configured to display an image; and a resin case that holds the display module. The resin case includes: an outer portion having an outer side surface facing the outer side of the resin case; and an inner portion having an inner side surface facing the inner side of the resin case. The inner portion has a gate forming portion, the gate forming portion having a first surface and a second surface facing away from the first surface, the second surface of the gate forming portion being separated from the outer side surface via a space portion of the resin case. The inner portion has a rib extending from the inner side surface and connected to the gate forming portion, the rib having an opening (hole) that forms the space portion of the resin case.

[0022] For the display device according to the second aspect, the cavity corresponding to the resin shell is filled with resin while the resin flow is changed by the resin flow changing portion of the space portion forming the resin shell. Therefore, the resin ejected from the resin injection port hits the opposite resin flow changing portion that changes the resin flow. This reduces the momentum of the resin ejected from the resin injection port, and thus the rebound of the resin in the cavity can be reduced. Therefore, the cavity can be filled with resin with less uneven density of the resin in the cavity, and thus, external defects such as whitening of the outer side surface due to differences in shrinkage of the resin, and generation of patterns on the outer side surface of the product that match the rebounded resin flow are reduced. As a result, a display device with fewer external defects can be obtained without changing the molding conditions, only by forming the space portion by the resin flow changing portion.

[0023] (11) According to a preferred embodiment of the display device described above, the second surface is provided between the first surface and the outer side surface in a direction in which the gate forming portion extends.

[0024] (12) Based on a preferred embodiment of any one of the above-mentioned display devices, the second surface includes a concave cut surface (undercut surface).

[0025] (13) Based on a preferred embodiment of any of the above-mentioned display devices, in the width direction perpendicular to the direction in which the gate forming portion extends, the space portion of the resin housing has a width greater than the width of the gate forming portion. According to this structure, the resin flow changing portion matching the space portion of the above-mentioned width can shift the resin flow toward the outer side surface forming portion after branching by the width of the resin flow changing portion, so that the momentum of the resin flow after branching can be further reduced.

[0026] (14) Based on a preferred embodiment of any of the above-mentioned display devices, in the direction in which the gate forming portion extends, the space portion of the resin housing has a height higher than the height of the gate forming portion. According to this structure, the resin flow changing portion matching the space portion of the above-mentioned height can increase the length of the flow path of the resin toward the outer side surface forming portion after branching by the height of the resin flow changing portion, so that the momentum of the resin flow after branching can be further reduced.

[0027] (15) Based on the preferred embodiment according to any one of the above-mentioned display devices, the first surface of the gate forming portion is configured to face the resin injection gate while molding the resin case.

[0028] (16) Based on the preferred embodiment according to any one of the above-mentioned display devices, the first surface and the second surface of the gate forming portion are disposed away from each other in the resin injection direction for molding the resin case.

[0029] (17) According to any one of the preferred embodiments of the display device described above, the space portion of the resin case is formed by filling a cavity corresponding to the resin case with resin while changing the resin flow by the resin flow changing portion.

[0030] (18) Based on any of the above preferred embodiments of the display device, the second surface is disposed directly facing the inner side surface via a space portion of the resin case.

[0031] (19) Based on the preferred embodiment according to any one of the above-mentioned display devices, the gate forming portion has a thickness greater than a thickness of the rib portion.

[0032] The present invention provides a display device and a method for manufacturing a resin molded product capable of reducing external defects without changing molding conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Referring now to the accompanying drawings which form a part of this original disclosure:

[0034] Figure 1 is a perspective view of a display device according to first to third embodiments;

[0035] Figure 2 is a side view of a display device according to the first to third embodiments;

[0036] Figure 3 is a rear view of the front housing of the display device according to the first to third embodiments;

[0037] Figure 4 yes Figure 3 An enlarged cross-sectional view of a Z portion of the front housing;

[0038] Figure 5 is a front view of the outer periphery of the space portion of the display device according to the first embodiment;

[0039] Figure 6 is a flow chart showing a method for manufacturing a front housing according to a first embodiment;

[0040] Figure 7 is a flow chart showing a cavity forming process according to the first embodiment;

[0041] Figure 8 is a flowchart showing a front housing molding process according to the first embodiment;

[0042] Fig. 9 is a schematic diagram showing a state in which a movable mold and a sliding mold are made movable toward a first fixed mold and a second fixed mold in the method for manufacturing a front housing according to the first embodiment;

[0043] Fig.10is a schematic diagram showing a state in which a first fixed mold, a second fixed mold, a movable mold, and a sliding mold are butted against each other to form a cavity in the method for manufacturing the front housing according to the first embodiment;

[0044] Fig.11 is a schematic diagram showing a state in which a cavity is filled with resin while a resin flow is changed by a resin flow changing portion in a method for manufacturing a front case according to a first embodiment;

[0045] Fig.12 is a schematic diagram showing a state in which a gate forming portion is formed in the method for manufacturing the front housing according to the first embodiment;

[0046] Fig.13 is Fig.12 A cross-sectional view along line XIII-XIII;

[0047] Fig.14 is a schematic diagram showing a state in which a resin is filled to an outer side surface forming portion in a method for manufacturing a front housing according to a first embodiment;

[0048] Fig.15 is a perspective view showing the outer periphery of a space portion of a front case formed by the method for manufacturing a front case according to the first embodiment;

[0049] Fig.16 is a schematic diagram showing a state in which a cavity is filled with resin injected from a cold runner in a method for manufacturing a front housing according to a second embodiment;

[0050] Fig.17 is a perspective view showing the outer periphery of a space portion of a front case formed by a method for manufacturing a front case according to a third embodiment; and

[0051] Fig.18 : is a plan view showing the outer periphery of the space portion of the front case formed by the method for manufacturing the front case according to the third embodiment. DETAILED DESCRIPTION

[0052] Selected embodiments will now be described with reference to the accompanying drawings. It will be apparent to those skilled in the art from this disclosure that the following description of the embodiments is provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

[0053] First embodiment

[0054] Reference Figures 1 to 5 The structure of the display device 100 is described. The display device 100 is an LCD TV. The display device 100 may be an organic EL (electroluminescence) TV instead of an LCD TV.

[0055] like Figure 1 and Figure 2 As shown, the display device 100 includes a display module 1 , a housing 2 (eg, a resin housing) and a back cover 3 .

[0056] The display module 1 has a function of displaying an image. The display module 1 includes a display unit 11 (e.g., a display), a light source 12, and a substrate 13. The display unit 11 is configured to display a video or an image using light from the light source 12. The display unit 11 includes a liquid crystal unit and a plurality of pixels. The pixel is configured to display a video or an image by changing the transmittance of the light emitted from the light source 12. The light source 12 is configured to illuminate the display unit 11 with light. The light source 12 includes a plurality of LEDs (light emitting diodes) arranged on the back side of the display unit 11. Specifically, in the illustrated embodiment, a plurality of LEDs are arranged in a matrix and arranged directly behind the display unit 11 to form a direct-type backlight source. However, a plurality of LEDs can be arranged along the edge of the display unit 11 to form an edge-type backlight source. The substrate 13 has a control circuit. The substrate 13 is configured to output a video signal to the display unit 11 through the control circuit.

[0057] The rear cover 3 is formed of a resin material such as polystyrene and covers the substrate 13 .

[0058] The housing 2 is configured to accommodate the display module 1 and the like. More specifically, the housing 2 includes a front housing 21 and a rear housing 22. Here, the direction in which the front housing 21 and the rear housing 22 are arranged relative to each other is the X direction, the side of the front housing 21 in the X direction is the X1 direction, and the side of the rear housing 22 in the X direction is the X2 direction. The direction perpendicular to the X direction in the horizontal direction of the display device 100 is the Y direction, one side of the Y direction (the left side) is the Y1 direction, and the other side of the Y direction (the right side) is the Y2 direction. The direction perpendicular to the X direction and the Y direction is the Z direction, one side of the Z direction is the Z1 direction (upward direction), and the other side of the Z direction is the Z2 direction (downward direction). The front housing 21 is an example of a "housing" of the present disclosure.

[0059] The front housing 21 is a resin molded product made of a resin material. The front housing 21 is configured to accommodate the display module 1. The front housing 21 supports the display unit 11. In addition, the front housing 21 has an opening that exposes the display surface of the display unit 11. Therefore, the front housing 21 has a frame shape when viewed from the front of the display device 100. The rear housing 22 is made of a metal sheet. The rear housing 22 is attached to the front housing 21 from the back side. In the illustrated embodiment, the rear housing 22 is made of a metal sheet. However, the rear housing 22 can be a resin molded product made of a resin material. In the illustrated embodiment, as Figure 2As shown, when the front case 21 is attached to the rear case 22 , an internal space of the display device 100 is formed between the front case 21 and the rear case 22 , and the display unit 11 and the light source 12 are disposed in the internal space.

[0060] Front housing

[0061] The front housing 21 will be described in detail below.

[0062] like Figure 3 and Figure 4 As shown, the front housing 21 has: an outer side portion having an outer side surface 121 and an inner side portion having an inner side surface 122. The outer side surface 121 is a surface facing the outer side of the housing 2. That is, the outer side surface 121 is a surface of the front housing 21 visible to the user of the display device 100. In particular, when the front housing 21 is attached to the rear housing 22, the outer side portion is exposed to the outside of the display device 100. The outer side surface 121 has a front surface that forms the frontmost surface of the housing 2 and faces the front (X1 direction) and four outer side surfaces (Y1, Y2, Z1 and Z2 directions) that form the outermost surface of the housing 2 and face outward relative to the center of the display device 100. The inner side surface 122 is a surface facing the inner side of the housing 2. That is, the inner side surface 122 is a surface of the front housing 21 that is not visible to the user of the display device 100. In particular, the inner side portion is arranged in the internal space of the display device 100, so that when the front housing 21 is attached to the rear housing 22, the inner side portion is not exposed to the outside of the display device 100.

[0063] The inner side portion (inner side surface 122 ) of the front housing 21 has a base surface portion (base surface portion) 122 a , a plurality of rib portions 122 b , and a plurality of gate forming portions 122 c .

[0064] The base surface 122a is a surface provided on the rear side of the outer side surface 121. The base surface 122a is a substantially L-shaped cross section. Figure 4 As shown, the base face 122a is substantially L-shaped when viewed in a cross-sectional view. The base face 122a has a frame shape. Specifically, the base face 122a has a rear surface facing rearward (X2 direction) and four inner side surfaces facing inward relative to the center of the display device 100 (Y1, Y2, Z1 and Z2 directions). The rear surface of the base face 122a has a horizontal edge extending in the Y direction and a vertical edge extending in the Z direction.

[0065] The rib 122b has a flat shape. Figure 3(twenty-six) ribs 122b are provided on the base face 122a. The ribs 122b are arranged relative to each other along the base face 122a. Specifically, twelve ribs 122b are arranged along each horizontal edge of the base face 122a, and one rib 122b is arranged along each vertical edge of the base face 122a. Of course, as needed and / or desired, the number of ribs 122b arranged along the horizontal edges can be greater than or less than twelve, and the number of ribs 122b arranged along the vertical edges can be greater than one. The ribs 122b protrude from the base face 122a (inner side 122) in the X2 direction (substantially perpendicular to the direction of the base face 122a). Each rib 122b extends in a specific direction (hereinafter referred to as the D direction). Specifically, each rib 122b arranged along the horizontal edge of the base face 122a extends in the Y direction, and each rib 122b arranged along the vertical edge of the base face 122a extends in the Z direction. In the illustrated embodiment, the rib 122b is disposed to be spaced apart from the inner surface of the base surface 122a via a gap therebetween. The wall thickness Tr of the rib 122b is less than the average wall thickness between the outer surface 121 and the base surface 122a. The wall thickness Tr of the rib 122b is preferably about 25% to about 35% of the average wall thickness between the outer surface 121 and the base surface 122a. The rib 122b may be disposed at one to twenty-five locations on the base surface 122a, or at twenty-seven to more locations.

[0066] The resin front housing 21 is formed by the resin injected from the resin injection port 71 of the hot runner 7, and at the same time, the gate forming portion 122c is formed (see Fig.11 ). That is, the gate forming portion 122c is a portion formed in order to form the front housing 21 by a direct gate method using the hot runner 7. The gate forming portion 122c is substantially cylindrical. The gate forming portion 122c has a resin injection port 71 (see Fig.10 ). Therefore, the resin injection gate 8 connected to the resin injection port 71 of the hot runner 7 at the gate forming portion 122c has a diameter that matches the diameter of the resin injection port 71 of the hot runner 7. The gate forming portion 122c extends in a direction parallel to the X2 direction (the direction in which the rib 122b protrudes). The gate forming portion 122c is integrally provided with the rib 122b. A plurality of (in Figure 3 The gate forming portion 122c may be set at one to nineteen locations, or twenty-one or more locations. The hot runner 7 is a molding tool for heating and melting the runner during injection molding. For example, the resin injection port 71 of the hot runner 7 is a nozzle head of the hot runner 7. Here, the resin injection gate 8 is a small opening in the model or mold, through which the resin enters the cavity 9 of the model or mold corresponding to the front housing 21 (see Fig.10 ). In the illustrated embodiment, each gate forming portion 122c includes a first surface 122e and a second surface 122f facing away from the first surface 122e. Specifically, in the illustrated embodiment, the first surface 122e faces the X2 direction, while the second surface 122f faces the X1 direction. While molding the front housing 21, the first surface 122e also faces the resin injection gate 8. Therefore, the first surface 122e can include gate residues or witness marks. However, of course, after the front housing 21 is molded, the gate residues can be removed from the first surface 122e. Further, in the illustrated embodiment, the hot runner 7 can be a runner system with a hot gate function, a valve gate hot runner system, or any other required and / or desired system.

[0067] Space Department

[0068] like Figure 4 and Figure 5 As shown, the front shell 21 of the first embodiment has a space portion 122d formed between the gate forming portion 122c of the inner side surface 122 and the outer side surface 121. That is, the gate forming portion 122c of the inner side surface 122 and the outer side surface 121 are not directly integrally provided, but are integrally provided through the rib 122b. Therefore, in the illustrated embodiment, each of the ribs 122b extending from the inner side surface 122 and connected to the gate forming portion 122c has an opening portion that forms the space portion 122d. In the illustrated embodiment, the second surface 122f of the gate forming portion 122c is arranged to be separated from the outer side surface 121 and the inner side surface 122 (the rear surface of the base surface portion 122a) respectively via the space portion 122d. Specifically, as Figure 4 and Figure 5 As shown in FIG. 1 , in the X direction in which the gate forming portion 122c extends, the second surface 122f is disposed between the first surface 122e and the outer side surface 121. Figure 4 and Figure 5 As shown, the second surface 122f is opposite to the inner surface 122 (the rear surface of the base surface portion 122a) via the space portion 122d. Further, the space portions 122d are respectively provided at locations corresponding to the gate forming portions 122c. Therefore, in the illustrated embodiment, the number of the space portions 122d is the same as the number of the gate forming portions 122c ( Figure 3 Twenty in the middle).

[0069] Reference Figure 4 and Figure 5 , showing in more detail one of the space portions 122d located in the Z portion of the front housing 21 (see Figure 3 ). Specifically, one of the space portions 122d located on one of the vertical edges of the base surface portion 122a is shown in more detail. Since the structure of the space portion 122d is the same, Figure 4 and Figure 5 The description of the space portion 122d shown is also applicable to the other space portions 122d. When viewed from the Y1 direction (a direction in the thickness direction of the rib 122b), the space portion 122d has a substantially rounded rectangular shape. The space portion 122d is a through hole that penetrates the rib 122b in the Y direction (the thickness direction of the rib 122b). In the Z direction (the width direction perpendicular to the direction in which the gate forming portion 122c extends), the width Ws of the space portion 122d is greater than the width Wg of the gate forming portion 122c. In the X direction (the direction in which the gate forming portion 122c extends), the height Hs of the space portion 122d is greater than the height Hg of the gate forming portion 122c. In addition, in the Y direction (the thickness direction of the rib 122b), similar to the thickness Tr of the rib 122b, the thickness Ts of the space portion 122d is less than the average wall thickness between the outer side surface 121 and the base surface portion 122a. The thickness Ts of the space portion 122d is preferably about 25% to about 35% of the average wall thickness between the outer side surface 121 and the base surface portion 122a. The shape of the space portion 122d may be semicircular or the like, and is not limited to a substantially circular rectangular shape.

[0070] The end face of the space portion 122d on the side of the gate forming portion 122c is a surface formed by the resin collision surface 51a of the flow changing section 51 of the sliding mold 5 (described later). The end face of the space portion 122d includes the second surface 122f of the gate forming portion 122c, and is a plane extending in the D direction. That is, the end face is a plane extending in a direction perpendicular to the resin injection direction (i.e., the resin injection direction, hereinafter referred to as the J direction) in which the resin is ejected from the resin injection port 71 of the hot runner 7. In addition, as Figure 4 and Figure 5 As shown, in the illustrated embodiment, the first surface 122e and the second surface 122f are disposed away from each other in the resin injection direction for molding the front housing 21. Therefore, in the illustrated embodiment, the end surface of the space portion 122d including the second surface 122f of the gate forming portion 122c is formed as a concave cut surface.

[0071] Method for manufacturing front housing

[0072] Reference Figures 6 to 15 A method for manufacturing the front housing 21 as a resin molded product (e.g., a method for manufacturing a resin molded product) is described. The method for manufacturing the front housing 21 is a process of filling with resin so that no outer defects (whitening, flow marks, etc.) appear on the outer side surface 121 of the front housing 21 without extending the molding cycle of the front housing 21 or increasing the wall thickness of the front housing 21.

[0073] like Figure 6Specifically, in step S1, a plurality of resin molding dies (e.g., a movable mold 4, a sliding mold 5, and a fixed mold 6) are brought into contact with each other to form a cavity 9 (see FIG. 1 ) having a shape corresponding to the front housing 21 (e.g., a resin molding). Fig. 9 and Fig.10 ).

[0074] More specifically, in Figure 7 In the subroutine of the cavity forming process shown in FIG. 1 , step S1 of forming the cavity 9 includes step S11 of making the movable mold 4, the sliding mold 5 and the fixed mold 6 abut against each other (see FIG. 1 ). Fig. 9 and Fig.10 ). In the illustrated embodiment, the movable mold 4 is provided with an outer side surface forming portion 41 that forms the outer side surface 121 of the front shell body 21. The sliding mold 5 is provided with a flow changing portion 51. Specifically, in the illustrated embodiment, the flow changing portion 51 of the sliding mold 5 is provided to form a space portion 122d. Since the front shell body 21 has a plurality of space portions 122d corresponding to the gate forming portion 122c, the sliding mold 5 can be provided with a plurality of flow changing portions 51 corresponding to the plurality of space portions 122d. In the illustrated embodiment, the sliding mold 5 can be divided into a plurality of mold portions, each mold portion having at least one flow changing portion 51, so that the mold portion is slidable in different directions relative to the fixed mold 6. Referring to Figures 9 to 14 , one of the mold parts of the sliding mold 5 forming one of the space parts 122d is described in detail. Since the structures of the mold parts are the same or similar to each other, Figures 9 to 14 The description of the mold part of the sliding mold 5 shown is also applicable to the other mold parts. Figures 9 to 14 , shows a method for manufacturing a portion of the front housing 21 using a mold portion of a slide mold 5. Since the structures of the mold portions are identical or similar to each other, Figures 9 to 14 The description of the method of manufacturing a portion of the front housing 21 using the mold portion of the sliding mold 5 is also applicable to the method of manufacturing the entire front housing 21 using the mold portion of the sliding mold 5. In the illustrated embodiment, with the first fixed mold 61 and the second fixed mold 62 of the fixed mold 6 already installed, the movable mold 4 and the sliding mold 5 (mold portion) are moved relative to the fixed mold 6 until they abut against the first fixed mold 61 and the second fixed mold 62.

[0075] In step S12, the hot runner 7 is inserted into the space formed by the first fixed mold 61 and the second fixed mold 62 (see Fig.10 That is, the hot runner 7 moves to the space between the first fixed mold 61 and the second fixed mold 62 until the resin injection port 71 of the hot runner 7 abuts against the resin injection gate 8. After the hot runner 7 moves, the subroutine of the cavity forming process ends, and the process enters step 2.

[0076] like Figure 6 As shown, in step S2, the front housing molding process is performed. That is, in step 2, the front housing 21 (resin molded product) is formed by directly injecting the resin from the resin injection port 71 into the resin injection gate 8 and filling the cavity 9 with the resin (see Fig.11 ).

[0077] More specifically, in Figure 8 In the subroutine of the front housing molding process shown in FIG. 1 , the step S2 of filling the cavity 9 with resin to mold the front housing 21 includes steps S21 to S26, wherein the cavity 9 is filled with resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changing portion 51 of the sliding mold 5 disposed opposite to the resin injection gate 8 (see FIG. 1 ). Fig.11 and Fig.12 ). Specifically, in step S2 of forming the front housing 21, when the resin flow hits the resin collision surface 51a facing the resin injection gate 8, the cavity 9 is filled with resin while changing the resin flow by the resin flow changing portion 51 having the resin collision surface 51a. Here, the resin flow changing portion 51 is the front end portion of the sliding mold 5, and when the cavity 9 is filled with resin, it is located between the gate forming portion 122c and the outer side surface forming portion 41 of the movable mold 4 that forms the outer side surface 121 of the resin molded product. The resin collision surface 51a is a plane extending in the D direction. That is, the resin collision surface 51a is a plane extending in a direction perpendicular to the J direction (resin injection direction) of the resin ejected from the resin ejection port 71 of the hot runner 7. The resin collision surface 51a faces the resin injection gate 8 in the J direction. More specifically, the resin collision surface 51a faces the resin injection gate 8 in the Op direction (i.e., the mold opening direction of the movable mold 4).

[0078] In step S21, resin is injected from the resin injection port 71 of the hot runner 7. Therefore, resin is injected from the resin injection gate 8 (see Fig.12 ). In step S22, the resin flows into the gate forming portion 122c. That is, in step S22, by causing the resin to flow toward the resin flow changing portion 51, the gate forming portion 122c is formed between the resin flow changing portion 51 and the resin injection gate 8, thereby serving as a non-outer side portion of the interior of the front housing 21. Here, the non-outer side portion of the front housing 21 is a portion that is provided on the inner side of the front housing 21 and is not exposed to the outer side of the front housing 21 when the front housing 21 is attached to the rear housing 22.

[0079] In step S23, the resin flow is branched by the resin flow changing section 51 (see Fig.13). At this time, the resin flow ejected from the resin injection port 71 is changed into a direction substantially perpendicular to the J direction by the resin flow changing portion 51. Step S23 is a step of branching the resin by changing the resin injected from the resin injection gate 8 using the resin flow changing portion 51 of the sliding mold 5. That is, in step S23, the resin flow changing portion 51 branches the resin flow injected from the resin injection gate 8. More specifically, in step S23, the resin flow changing portion 51 causes the resin flow injected from the resin injection gate 8 to branch in two directions intersecting with the J direction of the resin injected from the resin injection gate 8. Specifically, in step S23, the resin collision surface 51a causes the resin flow injected from the resin injection gate 8 to branch in two directions intersecting with the J direction of the resin injected from the resin injection gate 8. Furthermore, in step S23, in the case where the slide mold 5 provided with the resin flow changing portion 51 having a width Wm larger than the width Wg of the gate forming portion 122c in the direction perpendicular to the J direction is disposed relative to the fixed mold 6 and the movable mold 4, the cavity 9 is filled with the resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changing portion 51 (see Figure 5 and Fig.13 ). That is, the resin flow injected from the resin injection gate 8 matches the shape of the resin collision surface 51a of the resin flow change portion 51 of the slide mold 5, which is perpendicular to the J direction. At this time, the resin injected from the resin injection gate 8 is transferred in the direction perpendicular to the J direction by the width Wm of the resin flow change portion 51 of the slide mold 5, and flows toward the outer side surface forming portion 41. That is, the resin injected from the resin injection gate 8 flows into the bypass flow path F1 (space) of the portion of the rib 122b in the cavity 9.

[0080] In addition, in step S23, in the case where the slide mold 5 provided with the resin flow changing portion 51 having a height Hm higher than the height Hg of the gate forming portion 122c in the J direction is disposed relative to the fixed mold 6 and the movable mold 4, the cavity 9 is filled with the resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changing portion 51 (see Figure 5 and Fig.13 ). That is, the resin injected from the resin injection gate 8 flows along the resin collision surface 51a of the resin flow changing portion 51, and then flows into the space E1 in the cavity 9 where the rib 122b is formed. At this time, the resin injected from the resin injection gate 8 also flows along the face (surface) 51b of the resin flow changing portion 51 extending in the J direction. Then, the resin injected from the resin injection gate 8 flows downward in the J direction toward the outer side surface forming portion 41 by the height Hm of the resin flow changing portion 51 of the sliding mold 5. That is, the resin injected from the resin injection gate 8 flows downward from the space E1 in the cavity 9 where the rib 122b is formed toward the space E2 in the cavity 9 where the outer side surface 121 is formed.

[0081] In addition, the resin injected from the resin injection gate 8 flows along the resin collision surface 51a of the resin flow changing portion 51 of the sliding mold 5, and the resin collision surface 51a is perpendicular to the J direction in the flow path narrowed by the height Hm of the resin flow changing portion 51 in the J direction of the sliding mold 5.

[0082] In step S24, the resin flows into the rib forming portion 61a (see FIG. 1 ) of the first fixed mold 61 that forms the rib 122b of the front housing 21. Fig.11 and Fig.13 ). At this time, in step S24, the resin flows toward one side of the rib 122b which is the non-outer side portion extending in the D direction (specific direction) and toward the other side in the direction opposite to the D direction by branching by the resin flow changing portion 51. The resin injected from the resin injection gate 8 flows to fill the portion of the cavity 9 corresponding to the rib forming portion 61a and the portion of the cavity 9 corresponding to the outer side surface forming portion 41.

[0083] In step S25, the resin flows into the portion of the cavity 9 corresponding to the outer side surface forming portion 41 (see Fig.14 ). Next, in step S26, after cavity 9 is filled with resin, the process proceeds to step S3. In this way, the resin sequentially flows into the portion of cavity 9 corresponding to gate forming portion 122c, the portion of cavity 9 corresponding to rib forming portion 61a, and the portion of cavity 9 corresponding to outer side surface forming portion 41, thereby filling cavity 9.

[0084] In step S3, the resin in the cavity 9 is cooled. After the resin is cooled, in step S4, the front case 21 (resin molded product) is removed by opening the mold.

[0085] like Fig.15 As shown, the result of performing the method for manufacturing the front housing 21 as described above is that the front housing 21 is formed in which the space portion 122 d is formed between the gate forming portion 122 c and the outer side surface 121 .

[0086] Here, in the cavity 9, the gate forming portion 122c of the front case 21 is formed by filling the space formed by the slide mold 5 and the first fixed mold 61 with resin. In the rib 122b of the front case 21, a portion adjacent to the gate forming portion 122c side of the space portion 122d is formed by filling the bypass flow path F1 (space) formed in the cavity 9 by the resin flow changing portion 51 of the slide mold 5 and the first fixed mold 61 with resin.

[0087] In addition, by filling the space E1 formed by the portion of the slide mold 5 other than the resin flow changing portion 51, the first fixed mold 61, and the second fixed mold 62 with resin, a portion where the space portion 122d is not formed in the rib portion 122b of the front housing 21 is formed in the cavity 9. In the cavity 9, by filling the space E2 formed by the slide mold 5, the second fixed mold 62, and the movable mold 4, a portion of the front housing 21 having the outer side portion of the outer side surface 121 is formed.

[0088] The space E1 allows the bypass flow path F1 to communicate with the space E2. The volume of the space E1 is larger than the volume of the bypass flow path F1. The volume of the space E2 is larger than the volume of the space E1.

[0089] In this way, the housing 2 (particularly the front housing 21 ) of the display device 100 is formed as a resin molded product.

[0090] Effects of the First Embodiment

[0091] The first embodiment has the following effects.

[0092] In the first embodiment, as shown above, in step S2 of molding the front housing 21, steps S21 to S26 are provided, in which the cavity 9 is filled with resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changer 51 disposed opposite to the resin injection gate 8. Therefore, the resin ejected from the resin ejection port 71 hits the opposite resin flow changer 51 that changes the resin flow. Therefore, when the resin ejected from the resin ejection port 71 reaches the outer side surface 121, the resin will have a smaller momentum than the case where the ejected resin directly reaches the outer side surface 121, so that the rebound of the resin in the cavity 9 can be reduced. Therefore, the cavity 9 can be filled with resin while reducing the unevenness of the resin density in the cavity 9, so that the outer side defects such as the outer side surface 121 turning white due to the difference in the shrinkage of the resin or the outer side surface 121 of the product, which matches the rebound flow of the resin, are reduced. As a result, the outer side defects can be reduced by the resin flow changer 51 without changing the molding conditions. In addition, the resin flow changing portion 51 reduces outer defects (appearance defects) even when the resin injection speed increases (when the resin temperature is increased to reduce the viscosity), and therefore, the molding cycle can be shortened with the outer defects reduced.

[0093] In addition, in the first embodiment, as shown above, the steps S21 to S26 of filling the resin are provided with a step S23 in which the resin flow injected from the resin injection gate 8 is branched by the resin flow changing portion 51. According to this structure, the amount of resin can be dispersed by branching the resin flow, and thus the kinetic energy of each branched resin flow can be reduced compared to the original resin flow. As a result, the momentum of each branched resin flow can be reduced compared to the original resin flow, and thus the rebound of the resin in the cavity 9 can be further suppressed.

[0094] In addition, in the first embodiment, as shown above, the steps S21 to S26 of filling the resin are provided with a step S23, wherein the resin flow changing portion 51 branches the resin flow injected from the resin injection gate 8 into two directions intersecting with the J direction of the resin injected from the resin injection gate 8. According to this structure, whenever the branching of the resin flow increases, the amount of resin can be dispersed by the amount of increase in the branching of the resin flow. Therefore, by increasing the amount of branching of the resin flow, the kinetic energy of the resin flow of each branch can be further reduced compared to the original resin flow. As a result, the momentum of the resin flow of each branch can be further reduced compared to the original resin flow, and thus the rebound of the resin in the cavity 9 can be further suppressed.

[0095] In addition, in the first embodiment, as described above, the step S1 of forming the cavity 9 is provided with a step S11, wherein the movable mold 4 provided with the outer side surface forming portion 41 for forming the outer side surface 121 of the front shell 21, the sliding mold 5 provided with the resin flow changing portion 51, and the fixed mold 6 are brought into contact with each other. The step S23 of branching the resin flow is provided with a step S23, wherein the resin flow injected from the resin injection gate 8 is changed by the resin flow changing portion 51 of the sliding mold 5 to branch the resin. According to this structure, the resin flow changing portion 51 is provided in the sliding mold 5 separated from the fixed mold 6 and the movable mold 4. Therefore, when the front shell 21 is separated from the mold, the sliding mold 5 can slide to remove the resin flow changing portion 51 from the front shell 21, and therefore, the front shell 21 can be easily separated from the mold without being stuck by the resin flow changing portion 51.

[0096] In addition, in the first embodiment, as described above, step S2 of forming the front housing 21 is provided with step S21, in which the resin is injected from the resin injection gate 8, and step S22, in which the gate forming portion 122c is formed as a non-outer portion on the inner side of the front housing 21 between the resin flow changing portion 51 and the resin injection gate 8 by causing the resin to flow toward the resin flow changing portion 51. According to this structure, even if rebound occurs at the gate forming portion 122c, since the gate forming portion 122c is a non-outer portion, the front housing 21 does not have an outer defect, and thus the outer side of the front housing 21 can be kept good.

[0097] In addition, in the first embodiment, as described above, in the steps S21 to S26 of filling with resin, step S23 is included, in which, in a case where the slide mold 5 provided with the resin flow changing portion 51 having a width Wm larger than the width Wg of the gate forming portion 122c in the direction perpendicular to the J direction is attached to the movable mold 4 and the fixed mold 6, the cavity 9 is filled with resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changing portion 51. According to this structure, the branched resin flow toward the outer side surface molding portion 41 can be shifted by the width Wm of the resin flow changing portion 51, and thus the momentum of the branched resin flow can be further reduced.

[0098] In addition, in the first embodiment, as described above, in the steps S21 to S26 of filling with resin, step S23 is included, in which, in a case where the slide mold 5 provided with the resin flow changing portion 51 having a height Hm higher than the height Hg of the gate forming portion 122c in the J direction is attached to the movable mold 4 and the fixed mold 6, the cavity 9 is filled with resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changing portion 51. According to this structure, the length of the flow path of the branched resin toward the outer side surface forming portion 41 can be increased by the height Hm of the resin flow changing portion 51, and thus the momentum of the branched resin flow can be further reduced.

[0099] In addition, in the first embodiment, as described above, the steps S21 to S26 of filling the cavity 9 with the resin include a step S24 in which the resin flow changing portion 51 branches the resin toward one side of the rib 122b as the non-outer side extending in the direction D and toward the other side in the direction opposite to the direction D. According to this structure, the rib 122b can be used to branch the resin flow, and therefore, the structure of the resin molding die can be simpler than when a dedicated structure for branching the resin flow is provided.

[0100] In addition, in the first embodiment, as described above, step S2 of forming the front housing 21 is provided with steps S21 to S26, wherein the housing 2 of the display device 100 is formed as the front housing 21. According to this structure, the housing 2 of the display device 100 with fewer outer defects can be obtained without changing the molding conditions by the resin flow changing portion 51.

[0101] In addition, in the first embodiment, as described above, by filling the cavity 9 with resin while changing the flow of the resin through the resin flow changer 51, a space portion 122d is formed between the gate forming portion 122c on the inner side surface 122 and the outer side surface 121. According to this structure, the resin ejected from the resin injection port 71 hits the resin flow changer 51 that changes the resin flow in the opposite direction. This reduces the momentum of the resin ejected from the resin injection port 71, so that the rebound of the resin in the cavity 9 can be reduced. Therefore, the cavity 9 can be filled with resin with less uneven density of the resin in the cavity 9, so that external defects such as whitening of the outer side surface 121 due to differences in shrinkage of the resin and the generation of a pattern matching the rebounded resin flow on the outer side surface 121 of the product are reduced. As a result, it is possible to obtain a display device 100 with fewer external defects without changing the molding conditions, only by forming the space portion 122d through the resin flow changer 51.

[0102] In addition, in the first embodiment, as described above, in the Z direction (the width direction perpendicular to the direction in which the gate forming portion 122c extends), the width Ws of the space portion 122d is made larger than the width Wg of the gate forming portion 122c. According to this structure, the resin flow change portion 51 matched with the space portion 122d of the width Ws can shift the resin flow toward the outer side surface forming portion 41 after branching by the width Wm of the resin flow change portion 51, so that the momentum of the resin flow after branching can be further reduced.

[0103] In the first embodiment, as described above, the height Hs of the space 122d is made higher than the height Hg of the gate forming portion 122c in the X direction (the direction in which the gate forming portion 122c extends). According to this structure, the resin flow changing portion 51 matching the space 122d of the height Hs can increase the flow path length of the resin toward the outer side surface forming portion 41 after branching by the height Hm of the resin flow changing portion 51, so the momentum of the resin flow after branching can be further reduced.

[0104] Second embodiment

[0105] Now refer to Figure 1 , 2 16, a method for manufacturing the front housing 21 of the display device 100 according to the second embodiment will be described. In view of the similarity between the first and second embodiments, the components of the second embodiment that are the same as the components of the first embodiment will be given the same reference numerals as the components of the first embodiment. In addition, for the sake of brevity, the description of the components of the second embodiment that are the same as the components of the first embodiment may be omitted.

[0106] In the second embodiment, unlike the first embodiment, the resin is filled in the cavity 9 through a cold runner (cold sprue) 207. The same components as those of the first embodiment will not be described in the second embodiment.

[0107] like Figure 1 and 2 As shown, the display device 100 in the second embodiment includes a display module 1, a housing 2, and a rear cover 3. The housing 2 includes a front housing 21 and a rear housing 22. The front housing 21 is an example of a "housing" in the present disclosure.

[0108] Front housing

[0109] The front housing 21 will be described in detail below.

[0110] The front housing 21 has an outer portion having an outer surface 121 and an inner portion having an inner surface 122. The inner surface 122 has a base surface portion 122a, a rib portion 122b, and a gate forming portion 122c.

[0111] The gate forming portion 122c in the second embodiment is formed when the resin-made front shell 21 is molded by resin. In the illustrated embodiment, the resin is injected or dispensed from a nozzle (not shown) and delivered to the cavity 9 corresponding to the front shell 21 through the resin injection port 71 of the cold runner 207. Therefore, the front shell 21 is molded by the resin injected through the resin injection port 71 of the cold runner 207. The cold runner 207 is an unheated channel for delivering resin while the runner is cooled during the injection molding process. In the illustrated embodiment, the cold runner 207 is a channel formed on the fixed mold 6. As shown in FIG. Fig.16 As shown, the resin is filled into the cavity 9 through the cold runner 207, so during the injection molding process, the resin in the cold runner 207 is connected to the resin in the cavity 9 through the resin injection gate 8. After the injection molding process, the resin in the cold runner 207 is separated and removed from the front shell 21 at the resin injection gate 8. Here, in the illustrated embodiment, the resin in the cold runner 207 is shown with a different shade from the resin in the cavity 9 to clearly show the front shell 21, but the resin in the cold runner 207 is formed by the same resin as that in the cavity 9. In addition, in the illustrated embodiment, the gate type of the cold runner 207 can be any type as needed and / or desired, such as a direct gate, a side gate, a joint gate, a fan gate, an underwater gate, a banana gate, and a point gate. The remaining structure of the second embodiment is the same as that of the first embodiment.

[0112] Second Embodiment Effect

[0113] In the second embodiment, just like the first embodiment, in step S2 of forming the front housing 21, steps S21 to S26 are included, in which the cavity 9 is filled with resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changer 51 disposed opposite to the resin injection gate 8. Therefore, it is possible to reduce the outer defects by the resin flow changer 51 without changing the molding conditions. The remaining effects of the second embodiment are the same as those of the first embodiment.

[0114] Third embodiment

[0115] Now refer to Figure 1 , 2 , 17 and 18, a method for manufacturing the front housing 21 of the display device 100 according to the third embodiment will be described. In view of the similarity between the first and third embodiments, the components of the third embodiment that are the same as the components of the first embodiment will be given the same reference numerals as the components of the first embodiment. In addition, for the sake of brevity, the description of the components of the third embodiment that are the same as the components of the first embodiment may be omitted.

[0116] In the third embodiment, unlike the first embodiment, a plurality of ribs 320 are formed.

[0117] like Figure 1 and Figure 2 As shown, the display device 100 in the third embodiment includes a display module 1, a housing 2, and a rear cover 3. The housing 2 includes a front housing 21 and a rear housing 22. The front housing 21 is an example of a "housing" in the present disclosure.

[0118] Front housing

[0119] like Fig.17 and Fig.18 As shown, the front housing 21 has an outer portion having an outer side surface 121 and an inner portion having an inner side surface 122. The inner side surface 122 has a base surface portion 122a, a rib portion 320, and a gate forming portion 122c.

[0120] Each rib 320 has a main rib 321 , a first sub-rib 322 , a second sub-rib 323 , a third sub-rib 324 , a fourth sub-rib 325 , and a thick-walled portion 326 .

[0121] The main rib 321 has a flat shape. The main rib 321 protrudes from the base surface 122a in the X2 direction (a direction substantially perpendicular to the base surface 122a). The main rib 321 extends in a specific direction (hereinafter referred to as the D direction). The thickness of the main rib 321 is less than the average thickness between the outer side surface 121 and the base surface 122a. The thickness of the main rib 321 is preferably about 25% to about 35% of the average thickness between the outer side surface 121 and the base surface 122a.

[0122] Since each of the first to fourth sub-ribs 322 to 325 has the same structure, only the first sub-rib 322 will be described.

[0123] The main rib 322 has a flat shape. The first sub-rib 322 protrudes from the base surface 122a in the X2 direction (a direction substantially perpendicular to the base surface 122a). The first sub-rib 322 extends in a direction perpendicular to the D direction. The thickness of the first sub-rib 322 is less than the average thickness between the outer side surface 121 and the base surface 122a. The thickness of the first sub-rib 322 is preferably about 25% to about 35% of the average thickness between the outer side surface 121 and the base surface 122a.

[0124] The thick-walled portion 326 is a portion of the main rib 321 having a thickness Tt which is thicker than other portions. The thick-walled portion 326 is disposed at a position adjacent to the space portion 122d in the main rib 321. In the Z direction (width direction, perpendicular to the direction in which the gate forming portion 122c extends), the width Wt of the thick-walled portion 326 is greater than the width Wg of the gate forming portion 122c. In the X direction (the direction in which the gate forming portion 122c extends), the height Ht of the thick-walled portion 326 is substantially the same as the height Hg of the gate forming portion 122c. In the Y direction (thickness direction, perpendicular to the direction in which the gate forming portion 122c extends), the thickness Tt of the thick-walled portion 326 is less than the thickness Tg of the gate forming portion 122c. The remaining structure of the third embodiment is the same as that of the first embodiment described above.

[0125] Effects of the Third Embodiment

[0126] In the third embodiment, as in the first embodiment, in step S2 of forming the front housing 21, steps S21 to S26 are included, in which the cavity 9 is filled with resin while changing the resin flow from the resin injection gate 8 directly toward the cavity 9 by the resin flow changer 51 disposed opposite to the resin injection gate 8. Therefore, it is possible to reduce the outer defects by the resin flow changer 51 without changing the molding conditions.

[0127] In addition, in the third embodiment, as described above, not only the main rib 321 is provided, but also the first to fourth sub-ribs 322 to 325 are provided, which further branches the resin flow compared to when only the main rib 321 is provided, so that the outer defects can be further reduced. In addition, since the resin flow can be further branched, the outer defects can be reduced even when the resin injection speed increases (when the resin temperature is increased to reduce the viscosity), and therefore, the molding cycle can be further shortened while reducing the outer defects. The remaining effects of the third embodiment are the same as those in the first embodiment described above.

[0128] Modifications

[0129] The embodiments disclosed herein are illustrative in all aspects and not restrictive. The scope of the present invention is indicated by the claims rather than the description of the above embodiments, and further includes all modifications (variations) within the claims and their equivalents.

[0130] For example, in the first to third embodiments, an example is shown in which the resin molded product is the front case 21 of the display device 100, but the present invention is not limited thereto. In the present invention, the resin molded product may be a resin molded product other than a component of the display device.

[0131] In addition, in the first to third embodiments, the resin flow injected from the resin injection gate 8 through the resin flow changing portion 51 is branched in two directions intersecting with the J direction (resin injection direction), but the present invention is not limited thereto. In the present invention, the resin injected from the resin injection gate can be branched in three or more directions.

[0132] In addition, in the first to third embodiments, an example in which the gate forming portion 122c is formed in the rib 122b formed as a non-outer portion is shown, but the present invention is not limited thereto. In the present invention, the gate forming portion can be formed in a non-outer portion other than the rib, or in an outer portion.

[0133] In the first to third embodiments, the width Wm of the resin flow changing portion 51 is larger than the width Wg of the gate forming portion 122c, but the present invention is not limited thereto. In the present invention, the resin flow changing portion can have a width equal to or smaller than that of the gate forming portion.

[0134] In the first to third embodiments, the resin flow changing portion 51 has a height Hm higher than the gate forming portion 122c, but the present invention is not limited thereto. In the present invention, the resin flow changing portion can have a height equal to or smaller than the gate forming portion.

[0135] In the first to third embodiments, the width Ws of the space portion 122d is larger than the width Wg of the gate forming portion 122c, but the present invention is not limited thereto. In the present invention, the width of the space portion can be equal to or smaller than the width of the gate forming portion.

[0136] In the first to third embodiments, the height Hs of the space portion 122d is higher than the height Hg of the gate forming portion 122c, but the present invention is not limited thereto. In the present invention, the height of the space portion can be equal to or lower than the height of the gate forming portion.

[0137] In addition, in the first to third embodiments, an example of injecting resin into the cavity 9 through the resin injection gate 8 corresponding to the first surface 122e of the gate forming portion 122c is shown, but the present invention is not limited thereto. In the present invention, the resin injection gate can be provided at a position corresponding to the side of the gate forming portion 122c facing the inside or outside (i.e., the Y1, Y2, Z1, and Z2 directions) relative to the center of the display device 100. Figure 4 As shown, since the rib 122b is separated from the inner side surface of the base surface portion 122a and the outer side surface of the outer side surface 121 by a gap (e.g., a space portion) therebetween, even if the resin is injected into the cavity 9 from a position corresponding to the inner side surface of the gate forming portion 122c facing the inner side, no outer side defect will appear on the outer side surface 121. In this case, the surface of the rib 122b facing the rear (X2 direction) can be kept flat without a gate mark. In addition, in this case, the rib 122b can be formed without the space portion 122d.

[0138] In understanding the scope of the present invention, the term "comprise" and its derivatives as used herein are intended to be open terms describing the presence of stated features, elements, components, groups, wholes and / or steps, but do not exclude the presence of other unstated features, elements, components, groups, wholes and / or steps. The foregoing also applies to words with similar meanings, such as the terms "comprise", "have" and their derivatives. Moreover, unless otherwise indicated, the terms "part", "portion", "part", "member" or "element" when used in the singular can have the dual meaning of a single part or multiple parts.

[0139] As used herein, the following directional terms "forward," "rearward," "front," "rear," "up," "down," "above," "below," "upward," "downward," "top," "bottom," "side," "vertical," "horizontal," "vertical," and "lateral," and any other similar directional terms apply to these directions of the display device in an upright position. Therefore, these directional terms, as applied to the display device, should be interpreted relative to the display device in an upright position on a horizontal plane. The terms "left" and "right" are used to indicate "right" when referred to from the right side when viewed from the front of the display device, and "left" when referred to from the left side when viewed from the front of the display device.

[0140] It will also be understood that, although the terms "first" and "second" may be used herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another. Thus, for example, the first component discussed above may be referred to as the second component, and vice versa, without departing from the teachings of the present invention. The terms "attachment" or "attachment" as used herein include a configuration in which one element is directly fixed to another element by attaching one element directly to another element; a configuration in which one element is indirectly fixed to another element by attaching one element to an intermediate member and then being mounted to other elements; a configuration in which one element is integrated with another element, i.e., one element is essentially a part of the other element. This definition also applies to words of similar meaning, for example, "engagement", "connection", "coupling", "installation", "combination", "fixation" and their derivatives. Finally, the degree terms such as "substantially", "approximately" and "approximately" as used in the present invention represent the amount of deviation of the modified term, which does not significantly change the final result.

[0141] Although only selected embodiments are used to illustrate the present invention, it is obvious that those skilled in the art can make various changes and modifications to this document from the present disclosure without departing from the scope of the present invention as defined by the appended claims. For example, unless otherwise specifically stated, the size, shape, position or orientation of various components can be changed as needed and / or desired, as long as these changes do not substantially affect their intended functions. Unless otherwise specifically stated, the components shown to be directly connected or in contact with each other can have intermediate components disposed between them, as long as the changes do not substantially affect their intended functions. The function of one element can be performed by two elements, and vice versa, unless otherwise specifically stated. The structure and function of one embodiment can be adopted in another embodiment. It is not necessary to have all advantages in a particular embodiment at the same time. Each feature that is different from the prior art, alone or in combination with other features, should also be considered as a separate description of the applicant's further invention, including the structural and / or functional concepts embodied by these features. For those skilled in the art of the present disclosure, it is obvious from the present disclosure that the following description of the embodiments is provided for illustration only and is not intended to limit the purpose of the present invention as defined by the appended claims and their equivalents.

Claims

1. A display device, characterized in that: have: A display module, the display module comprising a display configured to display an image; and a resin casing, the casing holding the display module, The resin housing comprises: an outer side portion having an outer side surface facing the outside of the resin housing; and an inner portion having an inner side surface facing the inner side of the resin case, The inner portion has a gate forming portion, the gate forming portion having a first surface and a second surface facing away from the first surface, the second surface of the gate forming portion being spaced apart from the outer side surface via a space portion of the resin case, The inner portion has a rib portion extending from the inner side surface and connected to the gate forming portion, and the rib portion has an opening forming the space portion of the resin case.

2. The display device according to claim 1, characterized in that The second surface is provided between the first surface and the outer side surface in the direction in which the gate forming portion extends.

3. The display device according to claim 1 or 2, characterized in that: The second surface includes a concave cut surface.

4. The display device according to claim 1 or 2, characterized in that: The space portion of the resin case has a width greater than a width of the gate forming portion in a width direction perpendicular to a direction in which the gate forming portion extends.

5. The display device according to claim 1 or 2, characterized in that: The space portion of the resin case has a height higher than a height of the gate forming portion in a direction in which the gate forming portion extends.

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