Housing unit, working machine, and method for manufacturing housing unit

Abstract

The objective of the present invention is to improve design properties while suppressing an increase in cost. A housing unit 11 of an impact tool 1 is configured to include: a housing main body 12 constituting a framework of the housing unit 11; and an inner plate 13 and an outer plate 14 formed as separate members from the housing main body 12. The outer plate 14 is formed integrally with the housing main body 12 in a state of being exposed from the surface of the housing body 12, and the inner plate 13 is formed integrally with the housing main body 12 and the outer plate 14 in a state of being partially exposed from the surface of the outer plate 14. This makes it possible to decorate the housing main body 12 with the inner plate 13 and the outer plate 14 while integrally forming the housing main body 12, the inner plate 13 and the outer plate 14. Therefore, the design properties of the impact tool 1 can be improved while suppressing an increase in cost.

Description

Housing unit, working machine, and method for manufacturing housing unit

[0001] The present invention relates to a housing unit, a working machine, and a method for manufacturing a housing unit.

[0002] In the impact driver (work machine) described in Patent Document 1 below, the outer shell of the impact driver is formed by a housing, which is formed by two-color molding. Specifically, a resin layer that forms the skeleton of the impact driver is injection molded, and a protective layer made of an elastic material such as elastomer is formed on the surface of the resin layer. In addition, a decorative plate is provided on the surface of the housing, and the decorative plate is attached to the housing so as to straddle the resin layer and the protective layer. This allows the protective layer to be formed continuously, reducing the number of gates in the mold.

[0003] Japanese Patent Application Laid-Open No. 2005-199406

[0004] However, the above housing leaves room for improvement in the following respects. While providing a decorative plate on the housing can improve the design of the impact driver, the decorative plate is attached to the two-color molded housing to form a unit. This can increase the cost of the unitized housing due to factors such as an increase in labor hours. Therefore, it is desirable to have a configuration for work machines such as impact drivers that can improve the design while suppressing increases in cost.

[0005] In consideration of the above, a first object of the present invention is to provide a housing unit, a working machine, and a manufacturing method of the housing unit that can improve design while suppressing increases in cost. A second object of the present invention is to provide a housing unit, a working machine, and a manufacturing method of the housing unit that are highly functional.

[0006] One or more embodiments of the present invention are a housing unit that forms the outer shell of a work machine, and includes: a first housing that forms the skeleton of the housing unit; a second housing that is made of a separate member from the first housing and is formed integrally with the first housing with at least a portion exposed from the surface of the first housing; and a third housing that is made of a separate member from the second housing and is formed integrally with the first and second housings with at least a portion exposed from the surface of the second housing.

[0007] One or more embodiments of the present invention are a housing unit in which the first housing and the second housing are configured in different colors, and the second housing and the third housing are configured in different colors.

[0008] In one or more embodiments of the present invention, the second housing is a housing unit made of a material that has higher mechanical strength or thermal conductivity than the first housing.

[0009] One or more embodiments of the present invention are a housing unit in which the first housing is made of a resin material and the second housing is made of a metal material.

[0010] In one or more embodiments of the present invention, the first housing is a housing unit that includes a handle portion that is gripped by an operator and a body portion that covers the motor of the work machine, and the second housing and the third housing are provided on the body portion.

[0011] One or more embodiments of the present invention are a housing unit in which the second housing has a vent hole formed therein, and the vent hole provides communication between the inside and outside of the housing unit.

[0012] In one or more embodiments of the present invention, the body portion extends in a predetermined direction, and the third housing is disposed at a position overlapping the air vent in the predetermined direction.

[0013] One or more embodiments of the present invention are a housing unit in which an opening is formed through the body portion in the thickness direction of the plate, and the third housing has a cover portion that covers the entire opening from the outside in the thickness direction of the first housing, and a portion of the cover portion is positioned spaced apart from the edge of the opening on the outside in the thickness direction of the plate.

[0014] One or more embodiments of the present invention are a housing unit in which a protective cover portion made of an elastic material is integrally formed on the surface of the first housing, and the protective cover portion surrounds the outer periphery of the cover portion with a gap therebetween.

[0015] In one or more embodiments of the present invention, the third housing is configured to include a base portion and a mark portion that protrudes from the base portion toward the surface side of the third housing, and the third housing is a housing unit that is embedded in the second housing with the tip of the mark portion protruding from the surface of the second housing.

[0016] In one or more embodiments of the present invention, the second housing is a housing unit configured to include a hole-shaped cutout portion in which the mark portion is located and which is formed integrally with the side of the mark portion, a buried portion which is located inside the cutout portion and which is formed integrally with the side of the mark portion, and a bridge portion which connects the second housing and the buried portion and which is positioned one step lower than the surface of the second housing.

[0017] In one or more embodiments of the present invention, there is provided a housing unit in which the second housing is provided outside the first housing in a plate thickness direction, and a magnet or a heat insulating member is embedded between the first housing and the second housing. In one or more embodiments of the present invention, there is provided a housing unit constituting an outer shell of a work machine, the housing unit including: a resin housing made of a resin material; a supported member located inside the housing unit and made of a hard material harder than the resin housing; and a support member made of a hard material harder than the first housing and formed integrally with the resin housing and configured to support the supported member, the resin housing having a through hole extending from an outer surface to an inner surface of the resin housing, the support member extending from the outer surface to the inner surface of the resin housing so as to fill the through hole, the support member having a support portion protruding inward from the inner surface of the resin housing, the support portion being configured to come into contact with the supported member and support the supported member.

[0018] One or more embodiments of the present invention are a work machine comprising a housing unit having the above-described configuration, a motor housed in the housing unit, and a tool holder that holds a tool tip and is actuated by driving the motor.

[0019] One or more embodiments of the present invention are a method for manufacturing a housing unit having the above-described configuration, comprising a first step of setting the first housing and the third housing inside a molding die, and a second step of injecting molten resin material into the molding die to integrally mold the second housing with the first housing and the third housing.

[0020] One or more embodiments of the present invention are a method for manufacturing a housing unit having the above-described configuration, comprising a first step of setting the integrally formed second housing and third housing inside a molding die, and a second step of injecting molten resin material into the molding die to integrally mold the first housing with the second housing and the third housing.

[0021] According to one or more embodiments of the present invention, it is possible to provide a housing unit, a working machine, and a method for manufacturing a housing unit that can improve design while suppressing increases in cost. Also, according to one or more embodiments of the present invention, it is possible to provide a housing unit, a working machine, and a method for manufacturing a housing unit that are highly functional. It is possible to improve design while suppressing increases in cost.

[0022] It is a longitudinal sectional view showing an impact tool according to this embodiment. It is a longitudinal sectional view showing an enlarged upper part of the impact tool shown in FIG. 1. It is a perspective view seen from the left front obliquely showing the left housing unit in the housing shown in FIG. 1. It is an exploded perspective view of the housing unit shown in FIG. 3. It is a perspective view showing an enlarged inner panel and outer panel shown in FIG. 4. It is a side view seen from the left showing the upper housing part in the housing unit shown in FIG. 3. (A) is a sectional view seen from the rear side of the middle part in the front-rear direction of the upper housing part shown in FIG. 6 (sectional view taken along line 7A-7A in FIG. 6), (B) is a sectional view seen from the rear side of the rear part of the upper housing part shown in FIG. 6 (sectional view taken along line 7B-7B in FIG. 6), and (C) is a sectional view seen from the rear side of the rear part of the upper housing part shown in FIG. 6 (sectional view taken along line 7C-7C in FIG. 6). It is an explanatory view for explaining the molding procedure 1 of the housing unit. It is an explanatory view for explaining the molding procedure 2 of the housing unit. It is a side view seen from the left showing the upper housing part in the housing unit of Modification 1. (A) is a sectional view seen from the rear side of the rear part of the upper housing part shown in FIG. 10 (sectional view taken along line 11A-11A in FIG. 10), and (B) is a sectional view seen from the upper side of the rear part of the upper housing part shown in FIG. 10 (sectional view taken along line 11B-11B in FIG. 10). It is an exploded perspective view showing the state where the outer panel and inner panel shown in FIG. 10 are disassembled from the housing body. It is an exploded perspective view showing the state where the outer panel, inner panel, and magnet in the housing unit of Modification 2 are disassembled from the housing body. It is a sectional view of the upper housing part in the housing unit of Modification 3, (A) is a sectional view seen from the rear side of the middle part in the front-rear direction of the upper housing part shown in FIG. 6 (sectional view taken along line 7A-7A in FIG. 6), (B) is a sectional view seen from the rear side of the rear part of the upper housing part shown in FIG. 6 (sectional view taken along line 7B-7B in FIG. 6), and (C) is a sectional view seen from the rear side of the rear part of the upper housing part shown in FIG. 6 (sectional view taken along line 7C-7C in FIG. 6).

[0023] An impact tool 1 as a work machine according to this embodiment will be described below with reference to the drawings. Note that arrows UP, FR, and LH shown as appropriate in the drawings respectively indicate the upper side, front side, and left side of the impact tool 1. In the following description, when the up-down, front-rear, and left-right directions are used, they refer to the up-down, front-rear, and left-right directions of the impact tool 1 unless otherwise specified.

[0024] As shown in Figures 1 and 2, the impact tool 1 is configured as an electric tool that performs fastening processing and the like by applying rotational force and impact force to a tip tool 50 such as a driver bit attached to the front end of the impact tool 1.

[0025] The impact tool 1 includes a housing 10 that forms the outer shell of the impact tool 1, a motor 24 housed in the housing 10, and a driving force transmission mechanism 30 that transmits the driving force of the motor 24 to the tool bit 50. Each component of the impact tool 1 will be described below.

[0026] (Regarding the Housing 10) When viewed from the left and right, the housing 10 is formed in a hollow, generally I-shape. Specifically, the housing 10 includes an upper housing portion 10A as a body portion that forms the upper end of the housing 10 and extends in the front-to-rear direction, a handle portion 10B that extends downward from a central portion of the upper housing portion 10A in the front-to-rear direction, and a lower housing portion 10C that forms the lower end of the housing 10.

[0027] A trigger 20 is provided at the upper end of the handle portion 10B, and the trigger 20 protrudes forward from the handle portion 10B and can be pulled rearward. A switch mechanism 21 is provided on the handle portion 10B behind the trigger 20. The switch mechanism 21 has a switch (not shown), and pulling the trigger 20 switches the switch from off to on.

[0028] A controller 22 is provided in the lower housing portion 10C. The controller 22 is electrically connected to a switch of the switch mechanism 21. A battery 23 is detachably attached to the lower housing portion 10C. The battery 23 is electrically connected to the controller 22, and supplies power to a motor 24, which will be described later. Details of the components of the housing 10 will be described later.

[0029] (Regarding the Motor 24) The motor 24 is housed in the rear end of the upper housing portion 10A and is electrically connected to the controller 22. The motor 24 has a drive shaft 24A whose axial direction is the front-to-rear direction. The rear end of the drive shaft 24A is rotatably supported by a first motor bearing 25 fixed to the housing 10. Meanwhile, the front end portion of the drive shaft 24A is rotatably supported by a second motor bearing 26, which is fixed to a gear case 27 housed in the upper housing portion 10A. The gear case 27 is formed in a substantially stepped cylindrical shape whose axial direction is the front-to-rear direction, and the second motor bearing 26 is fitted into approximately the center of the gear case 27. The front end of the drive shaft 24A is disposed within the gear case 27, protruding forward beyond the second motor bearing 26. A fan 28 is provided on the rear end portion of the drive shaft 24A so as to rotate integrally therewith.

[0030] (Regarding the driving force transmission mechanism 30) The driving force transmission mechanism 30 is composed of a rotary impact mechanism 40 that applies a rotational force and an impact force to the tip tool 50, and a reduction mechanism 32 that reduces the rotational force of the motor 24 and transmits it to the rotary impact mechanism 40.

[0031] (Regarding the reduction mechanism 32) The reduction mechanism 32 is configured as a planetary gear mechanism and is disposed inside the gear case 27. Specifically, the reduction mechanism 32 includes a sun gear 33 fixed to the front end of the drive shaft 24A of the motor 24, a ring-shaped ring gear 34 provided radially outward of the sun gear 33, and a plurality of idle gears 35 (three in this embodiment) provided between the sun gear 33 and the ring gear 34.

[0032] The ring gear 34 is held in the gear case 27 via a damper, and internal teeth are formed on the inner peripheral surface of the ring gear 34. The idle gear 35 is supported by needle rollers 36 provided on the carrier portion 41B of the spindle 41 so as to be rotatable with the front-to-rear direction as the axial direction. The idle gear 35 is also meshed with the internal teeth of the sun gear 33 and the ring gear 34. As a result, when the sun gear 33 rotates, the idle gear 35 rotates about the axis of the needle rollers 36 while revolving about the axis of the sun gear 33, thereby rotating the spindle 41.

[0033] (Regarding the Rotary Impact Mechanism 40) The rotary impact mechanism 40 includes a spindle 41, a hammer 42, and an anvil 45 serving as a tool holder.

[0034] The spindle 41 has a spindle shaft 41A as a substantially cylindrical shaft portion whose axial direction is the front-to-rear direction, and the spindle shaft 41A is arranged coaxially with the drive shaft 24A of the motor 24. Specifically, the sun gear 33 described above is inserted into the rear end portion of the spindle shaft 41A, and the rear end portion of the spindle shaft 41A is rotatably supported by a bearing 47 provided in the gear case 27. A carrier portion 41B extending radially outward from the spindle shaft 41A is provided on the rear end side of the outer periphery of the spindle shaft 41A, and the idle gear 35 described above is rotatably provided on the carrier portion 41B.

[0035] A pair of spindle cam grooves 41C are formed on the outer peripheral surface of the front portion of the spindle shaft 41A. When viewed from the radially outer side of the spindle shaft 41A, the pair of spindle cam grooves 41C extend in a generally V-shape. When viewed in cross section from the longitudinal direction, the spindle cam groove 41C is formed in a generally semicircular shape that is open radially outward of the spindle shaft 41A. A steel ball 43 is rotatably inserted into the front end of the spindle cam groove 41C.

[0036] The hammer 42 is formed in a generally cylindrical shape with its axial direction extending in the front-to-rear direction, and an insertion hole 42A extends through the center of the hammer 42 in the front-to-rear direction. The front portion of the spindle 41 is inserted into the insertion hole 42A, and the hammer 42 is rotatably supported by the spindle 41.

[0037] A pair of hammer cam grooves 42B are formed on the inner peripheral surface of the insertion hole 42A of the hammer 42. The hammer cam grooves 42B extend circumferentially of the hammer 42 when viewed from the front and are open toward the front. The rear end of the hammer cam groove 42B is formed in a generally V-shape that is open toward the front when viewed from the radially inner side of the hammer 42. The pair of hammer cam grooves 42B are disposed 180 degrees apart in the circumferential direction of the hammer 42. A steel ball 43 is rotatably inserted into the hammer cam groove 42B and is located at the rear end of the hammer cam groove 42B.

[0038] A rearward-opening housing groove 42C is formed in the radially intermediate portion of the rear surface of the hammer 42. The housing groove 42C extends circumferentially around the entire circumference of the hammer 42. A hammer spring 44, configured as a compression spring, is housed in the housing groove 42C, and the hammer spring 44 biases the hammer 42 forward. As a result, the steel ball 43 is held within the front end of the spindle cam groove 41C and the rear end of the hammer cam groove 42B, connecting the hammer 42 and spindle 41 so that they can rotate together. When the rotary impact mechanism 40 is activated, the steel ball 43 rolls within the spindle cam groove 41C and the hammer cam groove 42B, causing the hammer 42 to rotate relative to the spindle 41 and move in the forward-backward direction. The rear end of the hammer spring 44 is locked by a locking plate 48 disposed between the spindle 41 and the hammer 42.

[0039] A plurality of hammer claws 42D (three in this embodiment) are integrally provided on the front surface (one axial end surface) of the hammer 42. The thickness direction of each hammer claw 42D is the front-to-rear direction, and each hammer claw 42D is formed in the shape of a generally sector-shaped block that protrudes radially inward of the hammer 42 when viewed from the front, protruding forward from the hammer 42. The hammer claws 42D are arranged at equal intervals (every 120 degrees) around the circumference of the hammer 42.

[0040] The anvil 45 is formed in a generally stepped cylindrical shape that opens to the front, and is disposed in front of the hammer 42. Specifically, a connecting shaft 45A having a smaller diameter than the remaining portions is formed at the rear end of the anvil 45, and the connecting shaft 45A is rotatably inserted into the front end of the spindle shaft 41A. A longitudinally intermediate portion of the anvil 45 is rotatably held by a sleeve 46 that is held at the front end of the upper housing portion 10A. The tool bit 50 is attached inside the anvil 45 from the front side so as to be immovable relative to the anvil 45.

[0041] Three anvil claws 45B are provided on the outer periphery of the rear end portion of the anvil 45. Each anvil claw 45B is formed in a generally rectangular plate shape with its thickness in the front-to-rear direction and protrudes radially outward from the anvil 45. The anvil claws 45B are arranged at equal intervals (every 120 degrees) around the circumference of the anvil 45 and are also arranged between the hammer claws 42D of the hammer 42. In other words, the hammer claws 42D and the anvil claws 45B are arranged alternately around the circumference of the hammer 42 in a front view.

[0042] When the hammer 42 rotates, the side of the hammer claw 42D abuts against the side of the anvil claw 45B adjacent to it in the rotational direction, and the hammer claw 42D and the anvil claw 45B engage in the circumferential direction of the hammer 42. As a result, a rotational force is applied from the hammer 42 to the anvil 45, causing the anvil 45 to rotate together with the tool bit 50. When the rotational force (torque) for rotating the tool bit 50 exceeds a predetermined value, the hammer 42 rotates relative to the anvil 45 so that the hammer claw 42D overcomes the anvil claw 45B, and a striking force is applied from the hammer 42 to the anvil 45.

[0043] (Constituent Components of the Housing 10) As shown in Fig. 3, the housing 10 has a pair of left and right housing units 11 (only the left housing unit 11 is shown in Fig. 3), and the pair of housing units 11 are assembled together to form the housing 10. Below, the configuration of the housing units 11 will be described using the left housing unit 11.

[0044] As shown in Figures 3 to 7, the housing unit 11 is composed of a housing main body 12 as a first housing, an inner plate 13 as a third housing, an outer plate 14 as a second housing, and a protective cover portion 15.

[0045] The housing main body 12 constitutes the framework of the housing unit 11 and is made of a resin material. Specifically, the housing main body 12 constitutes the upper housing portion 10A, the handle portion 10B, and the lower housing portion 10C of the housing 10. A first recess 12A (see FIGS. 4 and 7A) is formed at the upper end (the portion constituting the upper housing portion 10A) of the housing main body 12 for accommodating an inner plate 13 and an outer plate 14 (described later). The first recess 12A is formed in a generally rectangular recessed shape that is open to the left and extends longitudinally in the front-to-rear direction. A second recess 12B (see FIGS. 4 and 7A) is formed at the bottom surface of the first recess 12A in a vertically intermediate portion. The second recess 12B is formed in a generally rectangular recessed shape that is open to the left and extends longitudinally in the front-to-rear direction. Openings 12C (see FIGS. 4 and 7B) are formed through the rear end of the first recess 12A, respectively, at vertically outer sides of the second recess 12B. The opening 12C is formed in a generally rectangular hole shape with the vertical direction as the longitudinal direction.

[0046] A pair of upper and lower body-side vents 12D are formed through the rear end of the housing body 12, vertically outside the first recess 12A. That is, four body-side vents 12D are formed through the housing body 12. The body-side vents 12D are formed as approximately elongated holes with the longitudinal direction in the front-to-rear direction, and the front-to-rear length of the body-side vent 12D on the outer side in the vertical direction is set shorter than the front-to-rear length of the body-side vent 12D on the inner side in the vertical direction. The body-side vents 12D are positioned vertically outside the opening 12C, and the body-side vents 12D and the opening 12C are aligned vertically.

[0047] The inner plate 13 is configured as a member for decorating the housing main body 12. The inner plate 13 is formed of a metal material, a resin material, or the like, and is formed in a color different from that of the housing main body 12. The inner plate 13 has an inner base portion 13A as a base portion and a mark portion 13B. The inner base portion 13A is formed in a substantially rectangular plate shape with the plate thickness direction in the left-right direction and the longitudinal direction in the front-rear direction. The outer shape of the inner base portion 13A corresponds to the outer shape of the second recess 12B of the housing main body 12, and the inner base portion 13A is disposed within the second recess 12B and is formed integrally with the housing main body 12 and an outer plate 14 (described later) (see FIG. 7A ).

[0048] As shown in FIG. 5 , the mark portion 13B is composed of letters, figures, symbols, etc., and protrudes to the left from the inner base portion 13A. In this embodiment, the mark portion 13B is a string of letters arranged in a front-to-back direction, written as "LOGOLOGO." Furthermore, if the mark portion 13B contains an alphabetic character with a closed hollow portion, such as the letter "O," the hollow portion penetrates the inner base portion 13A. In this case, a slit portion 13C penetrating in the vertical direction is formed in the inner base portion 13A on the right side of the character, and the slit portion 13C is formed so as to fit into the right end portion of the mark portion 13B.

[0049] Like the inner plate 13, the outer plate 14 is configured as a member for decorating the housing main body 12. The outer plate 14 is formed from a metal material, a resin material, or the like, and is formed in a color different from the housing main body 12 and the inner plate 13. When the outer plate 14 is formed from a metal material, the outer plate 14 is set to be formed from a material that has higher mechanical strength (tensile strength, etc.) and thermal conductivity than the housing main body 12.

[0050] The outer plate 14 is formed in a generally rectangular plate shape with its thickness extending in the left-right direction and its length extending in the front-rear direction. The outer shape of the outer plate 14 corresponds to the outer shape of the first recess 12A of the housing main body 12, and the outer plate 14 is disposed inside the first recess 12A and is formed integrally with the housing main body 12 and the inner plate 13 (see FIG. 7A ). Specifically, the inner plate 13 is embedded in the outer plate 14 with the surface (left surface) of the marking portion 13B exposed and visible. More specifically, the inner plate 13 is embedded in the outer plate 14 with the tip (left end) of the marking portion 13B protruding from the surface of the outer plate 14.

[0051] Therefore, when the outer plate 14 and the inner plate 13 are separated (when the outer plate 14 is in a standalone state), a hole-shaped cutout 14A for locating the mark portion 13B is formed penetrating the outer plate 14 in the left-right direction. That is, when the outer plate 14 is in a standalone state, a hole corresponding to the shape of the mark portion 13B is formed in the outer plate 14. Also, as described above, when the mark portion 13B contains an alphabetic character with a closed hollow portion therein, such as the letter "O," a filled portion 14B corresponding to the hollow portion is formed inside the cutout 14A corresponding to this character. This filled portion 14B is connected to the outer plate 14 by a pair of upper and lower bridge portions 14C extending in both up and down directions from the filled portion 14B, and the bridge portion 14C is located one step lower to the right than the surface of the outer plate 14. When the inner plate 13 is integrally formed with the outer plate 14, the bridge portion 14C is disposed within the slit portion 13C of the outer plate 14 and is formed integrally with the inner plate 13 (see FIG. 7B).

[0052] A pair of upper and lower ventilation tubes 14D are formed at the rear end of the outer plate 14, vertically outward of the cutout 14A. The ventilation tubes 14D are formed in a generally rectangular cylindrical shape and protrude to the right from the outer plate 14, positioned within the opening 12C (see FIGS. 7B and 7C). The interiors of the ventilation tubes 14D serve as plate-side ventilation holes 14E, which penetrate in the left-right direction and connect the interior and exterior of the housing 10. The plate-side ventilation holes 14E and the main-body ventilation holes 12D are located on the left-right outer sides of the motor 24. When the fan 28 rotates, air is drawn into the housing 10 through the plate-side ventilation holes 14E and the main-body ventilation holes 12D.

[0053] The protective cover portion 15 is made of an elastic material such as elastomer. The protective cover portion 15 is formed integrally with the surface of the housing main body 12 by two-color molding. The protective cover portion 15 is formed over substantially the entire housing main body 12 in the up-down direction, excluding the outer plate 14 and the main body vent hole 12D of the housing main body 12.

[0054] (Operations and Effects) Next, the operations and effects of this embodiment will be described while explaining the molding procedure of the housing unit 11.

[0055] (Regarding molding procedure 1) In molding procedure 1 for the housing unit 11, the housing main body 12 molded from a resin material and the inner plate 13 molded from a resin material or a metal material are prepared. Note that the protective cover portion 15 is formed integrally with the housing main body 12 by two-color molding. Then, the housing main body 12, the inner plate 13, and the outer plate 14 are molded integrally with each other by insert molding.

[0056] Specifically, the mold 60 is opened, and the housing body 12 and the inner plate 13 are set in the core of the mold 60 (first step, see the state shown in FIG. 8 (1)). Next, the mold 60 is clamped (see the state shown in FIG. 8 (2)). Then, molten resin material is injected into the mold 60 to integrally mold the outer plate 14, the housing body 12, and the inner plate 13 (second step, see the state shown in FIG. 8 (3)). This forms the housing unit 11. Thereafter, the mold 60 is opened, and the housing unit 11 is removed from the mold 60 (see the state shown in FIG. 8 (4)).

[0057] (Regarding Molding Procedure 2) In molding procedure 2 of the housing unit 11, the inner plate 13 and the outer plate 14 are prepared, and the inner plate 13 and the outer plate 14 are integrally molded by insert molding. Specifically, one of the inner plate 13 and the outer plate 14 is set in a molding die (not shown), and molten resin material is injected into the molding die to mold the other of the inner plate 13 and the outer plate 14, and to integrally mold the inner plate 13 and the outer plate 14. The material of one of the inner plate 13 and the outer plate 14 set in the molding die is not limited, and may be made of a material such as stone, wood, resin, or metal.

[0058] Next, the integrally formed inner plate 13 and outer plate 14 are molded integrally with the housing main body 12 by insert molding. Specifically, the mold 62 is opened, and the inner plate 13 and outer plate 14 are set in the core of the mold 62 (first step, see state (1) in FIG. 9 ). Next, the mold 62 is clamped (see state (2) in FIG. 9 ). Molten resin material is then injected into the mold 62 to integrally mold the housing main body 12 with the inner plate 13 and outer plate 14 (second step, see state (3) in FIG. 9 ). After molding the housing main body 12, the protective cover portion 15 is formed on the housing main body 12 by two-color molding. This completes the housing unit 11. After molding the protective cover portion 15, the housing unit 11 is removed from the two-color mold (see state (4) in FIG. 9 ).

[0059] As described above, the housing unit 11, which is a component of the housing 10, includes a housing main body 12 that forms the framework of the housing unit 11, and an inner plate 13 and an outer plate 14 that are separate members from the housing main body 12. The outer plate 14 is integrally formed with the housing main body 12 while being exposed from the surface of the housing main body 12, and the inner plate 13 is integrally formed with the housing main body 12 and the outer plate 14 while being partially exposed from the surface of the outer plate 14. As a result, as described above, the housing main body 12, inner plate 13, and outer plate 14 are integrally formed by insert molding, and the housing main body 12 can be decorated with the inner plate 13 and the outer plate 14. That is, compared to a structure in which the inner plate 13 and the outer plate 14 are attached to the housing main body 12, for example, the housing main body 12 can be decorated with fewer man-hours. Therefore, the design of the impact tool 1 can be improved while suppressing increases in cost.

[0060] Furthermore, the outer plate 14 is formed in a color different from that of the housing main body 12, and the inner plate 13 is formed in a color different from that of the housing main body 12 and the outer plate 14. This makes it possible to highlight the outer plate 14 relative to the housing main body 12, while also highlighting the exposed portion of the inner plate 13 relative to the outer plate 14. Furthermore, for example, by setting the colors of the outer plate 14 and the housing main body 12 to colors that are complementary to each other, and by setting the colors of the inner plate 13 and the outer plate 14 to colors that are complementary to each other, the outer plate 14 and the exposed portion of the inner plate 13 relative to the outer plate 14 can be effectively highlighted.

[0061] Furthermore, when the outer plate 14 is made of a metal material, the outer plate 14 is made of a material that has high mechanical strength or thermal conductivity relative to the housing body 12. This allows the outer plate 14 to function as a reinforcing member for the housing body 12 while also functioning as a heat dissipation portion. This increases the rigidity of the housing unit 11 and improves the heat dissipation of the housing unit 11. This improves the functionality of the housing unit 11. Furthermore, the housing body 12 and the outer plate 14 can have different textures. This further improves the design of the impact tool 1.

[0062] The housing main body 12 includes a handle portion 10B and an upper housing portion 10A provided above the handle portion 10B, and the inner plate 13 and the outer plate 14 are provided on the upper housing portion 10A. This allows the inner plate 13 and the outer plate 14 to be provided on the housing main body 12 while preventing the hand of an operator gripping the handle portion 10B from interfering with the inner plate 13 and the outer plate 14. In other words, the design of the impact tool 1 can be improved while ensuring the gripping performance of the housing 10.

[0063] Furthermore, plate-side ventilation holes 14E are formed through the outer plate 14 in the left-right direction, and the plate-side ventilation holes 14E connect the inside and outside of the housing unit 11. This allows the outer plate 14, which is a decorative member, to pass airflow for cooling mechanical components such as the motor 24 inside the housing 10, thereby improving the functionality of the housing unit 11.

[0064] Furthermore, the inner plate 13 is disposed at a position overlapping with the plate-side vent holes 14E in the front-rear direction. Specifically, the plate-side vent holes 14E are provided on both up-down sides of the rear end portion of the inner plate 13. Therefore, compared to a structure in which the plate-side vent holes 14E and the inner plate 13 are offset in the front-rear direction, the inner plate 13 can be provided in the upper housing portion 10A while preventing the upper housing portion 10A from becoming larger in the front-rear direction.

[0065] The inner plate 13 includes an inner base portion 13A and a mark portion 13B that protrudes outward in the plate thickness direction from the inner base portion 13A. The inner plate 13 is embedded in the outer plate 14 with the tip of the mark portion 13B protruding from the surface of the outer plate 14. This allows the mark portion 13B to be exposed three-dimensionally within the outer plate 14. This effectively improves the design of the impact tool 1.

[0066] The outer plate 14 has a cutout portion 14A, and the mark portion 13B of the inner plate 13 is disposed inside the cutout portion 14A of the outer plate 14. A filled portion 14B is disposed inside the cutout portion 14A, and the filled portion 14B is connected to the outer plate 14 by a bridge portion 14C. This makes it possible to form the outer plate 14 integrally with the inner plate 13, even if the mark portion 13B has a closed hollow portion such as the letter "O," by connecting the filled portion 14B corresponding to the hollow portion to the outer plate 14. This improves the design of the mark portion 13B.

[0067] In addition, in molding procedure 1 of the housing unit 11, the housing body 12, the inner plate 13, and the outer plate 14 are integrally molded by insert molding. This reduces the number of molding steps of insert molding, and enables the housing body 12, the inner plate 13, and the outer plate 14 to be integrally formed.

[0068] In molding procedure 2 of the housing unit 11, the integrally formed inner plate 13 and outer plate 14 are integrally molded with the housing main body 12 by insert molding. This allows the housing main body 12, inner plate 13, and outer plate 14 to be integrally formed by selecting a material such as a resin material or a metal material for one of the inner plate 13 and outer plate 14 depending on the application, for example.

[0069] (Modification 1 of Housing Unit 11) Next, Modification 1 of the housing unit 11 will be described. As shown in FIGS. 10 to 12 , in Modification 1, the vent cylinder portion 14D (plate-side vent hole 14E) is omitted from the outer plate 14. A pair of upper and lower cover portions 13D are formed at the rear end of the inner plate 13, and the cover portions 13D extend outward in the vertical direction from the rear end of the inner plate 13. The cover portions 13D cover the entire opening 12C from the outside in the plate thickness direction while maintaining communication between the interior of the opening 12C of the housing main body 12 and the outside of the housing unit 11. Specifically, the outer periphery of the cover portion 13D is disposed outward in the plate thickness direction of the housing main body 12 with a predetermined gap G1 from the edge portion 12C1 of the opening 12C.

[0070] An outer plate 14 is provided on the surface of the cover portion 13D, and the outer plate 14 makes the cover portion 13D invisible from the surface side. The outer periphery of the cover portion 13D is surrounded by a protective cover portion 15 with a predetermined gap G2 therebetween. As a result, the inside of the opening 12C communicates with the outside of the housing unit 11 via gaps G1 and G2 (see FIGS. 11A and 11B).

[0071] In the first modification of the housing unit 11, as described above, the cover portion 13D of the inner plate 13 covers the entire opening 12C from the outside in the thickness direction, and the outer periphery of the cover portion 13D is disposed with a predetermined gap G1 between the edge 12C1 of the opening 12C and the outside of the housing body 12 in the thickness direction. That is, the cover portion 13D of the inner plate 13 covers the opening 12C from the outside in the thickness direction while maintaining communication between the interior of the opening 12C of the housing body 12 and the outside of the housing unit 11. In other words, the opening 12C can be covered from the outside in the thickness direction of the housing body 12 while maintaining the ventilation function of the opening 12C. This improves the waterproof and dustproof properties of the impact tool 1 while ensuring the cooling of mechanical components such as the motor 24. This improves the functionality of the housing unit 11.

[0072] Furthermore, in the first modification of the housing unit 11, the outer periphery of the cover portion 13D is surrounded by the protective cover portion 15 with a predetermined gap G2 therebetween. This allows a labyrinth structure formed by the gaps G1 and G2 to be formed between the cover portion 13D and the housing main body 12. This effectively improves the waterproof and dustproof properties of the impact tool 1. It also improves the functionality of the housing unit 11.

[0073] (Modification 2 of Housing Unit 11) Next, Modification 2 of the housing unit 11 will be described. As shown in FIG. 13 , in Modification 2, a pair of upper and lower third recesses 12E are provided on the bottom surface of the first recess 12A of the housing main body 12, and the third recesses 12E are located on both sides of the second recess 12B in the vertical direction. Furthermore, in Modification 3, the housing unit 11 has a pair of magnets 16. The magnets 16 are formed in a substantially rectangular plate shape with the plate thickness direction in the left-right direction and the longitudinal direction in the front-rear direction. The magnets 16 are located in the third recesses 12E, are formed integrally with the housing main body 12 and the outer plate 14, and are embedded in the housing unit 11.

[0074] As a result, in the second modification of the housing unit 11, for example, screws used in fastening processing can be magnetized on the surface of the outer plate 14. This improves the operability of the impact tool 1. Also, the functionality of the housing unit 11 can be improved.

[0075] In the second modification, the magnet 16 is embedded in the housing unit 11, but the member embedded in the housing unit 11 is not limited to this. For example, although not shown in the drawings, a heat insulating plate filled with gas may be embedded in the housing unit 11.

[0076] (Modification 3 of Housing Unit 11) Next, Modification 3 of the housing unit 11 will be described. As shown in FIG. 14A , in Modification 3, the inner plate 13 is molded from a hard material, such as a hard resin material or a metal material, that is harder than the resin material constituting the outer plate 14. The molded inner plate 13 extends from the outer surface of the outer plate 14 to the inner surface of the outer plate 14 so as to fill the cutout portion 14A of the outer plate 14. The inner base portion 13A that protrudes inward from the inner surface of the outer plate 14 supports the outer periphery of the driving force transmission mechanism 30. The driving force transmission mechanism 30 is formed from a hard material, such as a metal material, that is harder than the resin material constituting the outer plate 14. This allows for strong support of the driving force transmission mechanism 30 and improves the wear resistance of the housing unit 11. Furthermore, if the inner plate 13 is molded from a soft material, such as an elastomer, that is softer than the resin material constituting the outer plate 14, vibration of the driving force transmission mechanism 30 can be suppressed. This improves the functionality of the housing unit 11. In this case, the outer periphery of the drive force transmission mechanism 30 may be supported only by the inner base portion 13A, or the outer periphery of the hammer case may be supported by both the inner base portion 13A and the housing main body 12.

[0077] 14(C), in Modification 3, the inner plate 13 is molded from a hard material, such as a hard resin or metal, that is harder than the resin material constituting the outer plate 14. The molded inner plate 13 extends from the outer surface of the outer plate 14 to the inner surface of the outer plate 14, filling the cutout portion 14A of the outer plate 14. The inner base portion 13A, which protrudes inward from the inner surface of the outer plate 14, supports the outer periphery of the motor 24. The motor 24 is formed from a hard material, such as a metal, that is harder than the resin material constituting the outer plate 14. This allows for strong support of the motor 24 and improves the wear resistance of the housing unit 11. Furthermore, if the inner plate 13 is molded from a soft material, such as an elastomer, that is softer than the resin material constituting the outer plate 14, vibration of the motor 24 can be suppressed. This improves the functionality of the housing unit 11. 14(C), the outer periphery of the motor 24 may be supported only by the inner base portion 13A, or by both the inner base portion 13A and the housing main body 12. The outer plate 14 is an example of a resin housing, the inner plate 13 is an example of a supporting member, the driving force transmission mechanism 30 and the motor 24 are examples of supported members, the cutout portion 14A is an example of a through hole, and the inner base portion 13A is an example of a supporting portion.

[0078] DESCRIPTION OF SYMBOLS 1...Impact tool (work machine), 10A...Upper housing portion (body portion), 10B...Handle portion, 11...Housing unit, 1112...Housing main body (first housing), 12C...Opening, 13...Inner plate (third housing), 13A...Inner base portion (base portion), 13B...Mark portion, 13D...Cover portion, 14...Outer plate (second housing), 14A...Punched portion, 14B...Filled portion, 14C...Bridge portion, 14E...Plate side ventilation hole (ventilation hole), 15...Protective cover portion, 24...Motor, 45...Anvil (tip tool holding portion), 50...Tip tool, 60...Molding die, 62...Molding die, G2...Gap

Claims

1. A housing unit that constitutes the outer casing of a work machine, The first housing, which constitutes the framework of the housing unit, A second housing is made of a separate component from the first housing and is integrally molded with the first housing such that at least a portion of it is exposed from the surface of the first housing, A third housing is formed from a separate component from the second housing, and is integrally molded with the first and second housings, with at least a portion of it exposed from the surface of the second housing. A housing unit equipped with [a specific feature / feature].

2. The housing unit according to claim 1, wherein the first housing and the second housing are composed of different colors, and the second housing and the third housing are composed of different colors.

3. The housing unit according to claim 1, wherein the second housing is made of a material that has higher mechanical strength or thermal conductivity than the first housing.

4. The housing unit according to claim 3, wherein the first housing is made of a resin material and the second housing is made of a metal material.

5. The first housing is, The handle portion that the worker grips, The body portion that covers the motor of the aforementioned work machine, It consists of, The housing unit according to claim 1, wherein the second housing and the third housing are provided on the body portion.

6. The housing unit according to claim 5, wherein the second housing has ventilation holes formed therein, and the inside and outside of the housing unit are in communication through the ventilation holes.

7. The housing unit according to claim 6, wherein the body portion extends in a predetermined direction, and the third housing is positioned to overlap with the ventilation hole in the predetermined direction.

8. The aforementioned body section has an opening formed through it in the direction of the plate thickness. The housing unit according to claim 5, wherein the third housing has a cover portion, the cover portion covers the entire opening from the outside in the thickness direction of the first housing, and a part of the cover portion is spaced apart from the edge of the opening in the thickness direction.

9. A protective cover made of an elastic material is integrally molded on the surface of the first housing. The housing unit according to claim 8, wherein the protective cover portion surrounds the outer periphery of the cover portion with a gap.

10. The 3-housing is The base part, A mark portion including letters, figures, or symbols protruding from the base portion toward the surface side of the third housing, It is composed of including, The housing unit according to claim 1, wherein the third housing is embedded in the second housing with the tip of the marked portion protruding from the surface of the second housing.

11. The preceding 2 housing is The mark portion is positioned inside, and a hole-shaped cutout portion is formed integrally with the side surface of the mark portion, A filling portion is positioned inside the cutout portion and is formed integrally with the side surface of the mark portion, A bridge portion connects the second housing and the fill portion, and is positioned one level lower than the surface of the second housing, The housing unit according to claim 10, comprising:

12. The second housing is provided on the outer side of the first housing in the thickness direction, The housing unit according to claim 1, wherein a magnet or a heat insulating member is embedded between the first housing and the second housing.

13. A housing unit that constitutes the outer casing of a work machine, A resin housing made of resin material, A supported member located inside the housing unit and made of a hard material with higher hardness than the resin housing, A support member is made of a hard material with higher hardness than the first housing, is integrally formed with the resin housing, and is configured to support the supported member, It has, The resin housing has a through hole that extends from the outer surface to the inner surface of the resin housing, A housing unit wherein the support member extends from the outer surface to the inner surface of the resin housing so as to fill the through hole, and the support member has a support portion that protrudes inward from the inner surface of the resin housing, and the support portion is configured to contact the supported member and support the supported member.

14. A housing unit according to any one of claims 1 to 13, The motor housed in the aforementioned housing unit, A tool holder that holds the tool tip and is operated by the motor, A vehicle used for construction work.

15. A method for manufacturing a housing unit according to claim 1, A first step of setting the first housing and the third housing inside the mold, A second step involves injecting molten resin material into the mold to integrally form the second housing with the first housing and the third housing, A method for manufacturing a housing unit equipped with the above.

16. A method for manufacturing a housing unit according to claim 1, A first step involves setting the integrally formed second housing and third housing inside the mold, A second step involves injecting molten resin material into the mold to integrally form the first housing with the second housing and the third housing, A method for manufacturing a housing unit equipped with the above.