Housing structure and display device

Abstract

A metal chassis (300) has a flat plate (310), a first side wall (320a) erected from a first edge part (312a) of the flat plate (310), and a first frame plate (340a) extending outward from a first tip (330a) of the first side wall (320a). A front frame (120) is attached from the outside to a first outer edge part (342a) of the first frame plate (340a). The first outer edge part (342a) of the first frame plate (340a) of the metal chassis (300) is provided with a plurality of first anchors (350a) at intervals of 40 mm or less. The front frame (120) is provided with a plurality of first protrusions (122a) at intervals of 40 mm or less. The plurality of first protrusions (122a) are combined with the plurality of first anchors (350a).

Description

Housing Structure, Display Device

[0001] The present disclosure relates to a housing structure and a display device.

[0002] A display device mounted on a vehicle includes, for example, a design resin component (also referred to as a front frame), a front plate (also referred to as a glass lens), and a metal frame. Display devices are required to have both mechanical strength and reduced weight. To achieve both of these objectives, insert molding combining a design resin component and a metal chassis is used (see, for example, Patent Document 1).

[0003] Japanese Unexamined Patent Publication No. 2023-113269

[0004] Insert molding combines the strength of resin and metal, and facilitates efficient production of components having complex shapes or functions. However, due to the difference in coefficient of linear expansion between resin and metal, stress is generated under high or low temperature environments, which makes resin cracking prone to occur. For this reason, resins such as PP (polypropylene), which has a high physical property value of tensile elongation, are used. On the other hand, PP has the property of being "difficult to wet". In other words, PP has poor adhesion for painting and printing, or poor adhesiveness for double-sided tape used to hold glass.

[0005] The present disclosure has been made in view of such circumstances, and an object thereof is to provide a technique for suppressing the occurrence of resin cracking when a general-purpose resin other than PP is combined with a metal.

[0006] In order to solve the above problem, a housing structure according to one aspect of the present disclosure includes a metal chassis having a flat plate, a side wall erected from an edge of the flat plate, and a frame plate extending outward from a distal end of the side wall, and a resin frame attached to an outer edge of the frame plate from an outside. A plurality of anchors are provided at intervals of 40 mm or less on the outer edge of the frame plate of the metal chassis, a plurality of protrusions are provided at intervals of 40 mm or less on the resin frame, and when the resin frame is attached to the metal chassis, the plurality of protrusions are combined with the plurality of anchors.

[0007] Another aspect of the present disclosure is also a housing structure. This housing structure comprises a metal chassis having a flat plate with adjacent first and second edges, a first lateral wall erected from the first edge, a first frame plate extending outward from the tip of the first lateral wall, a second lateral wall erected from the second edge, and a second frame plate extending outward from the tip of the second lateral wall, and a resin frame attached from the outside to the first outer edge of the first frame plate and the second outer edge of the second frame plate. A first anchor is provided on the first outer edge of the first frame plate of the metal chassis at a position of 7 mm or less from the first end of the first frame plate on the second frame plate side of the first frame plate, and a second anchor is provided on the second outer edge of the second frame plate of the metal chassis at a position of 7 mm or less from the second end of the second frame plate on the first frame plate side of the second frame plate, and a first projection and a second projection are provided on the resin frame, and when the resin frame is attached to the metal chassis, the first projection is combined with the first anchor and the second projection is combined with the second anchor.

[0008] According to this disclosure, when combining general-purpose resins other than PP with metal, the occurrence of resin cracking can be suppressed.

[0009] Figure 1 is a perspective view showing the structure of the display device according to this embodiment. Figure 2 is a cross-sectional view showing the structure of the display device. Figure 2 is an enlarged partial cross-sectional view. Figure 2 is a perspective view showing the structure of the front frame and metal chassis. Figure 4 is an enlarged partial perspective view. Figure 4 is an enlarged partial perspective view.

[0010] Before specifically describing the embodiments of this disclosure, an overview of the embodiments will be provided. This embodiment relates to a display device mounted in a vehicle, for example, in the rear seat. Insert molding is used in the display device, and a metal chassis and a front frame (also called a resin frame) are combined. The resin frame is formed from a general-purpose resin other than PP. In such a configuration, stress is generated due to the difference in the coefficients of thermal expansion between the resin and the metal in high-temperature or low-temperature environments, making the resin prone to cracking. In the display device according to this embodiment, multiple anchors for joining the resin are provided in the metal chassis. At that time, the spacing between the anchors is determined so that the stress in high-temperature and low-temperature environments is below an allowable value, taking into account the difference in the coefficients of thermal expansion between the resin and the metal. In addition, since localized stress is likely to occur if the resin is placed outside the end of the metal, the anchors are placed near the end of the metal. In the following description, "parallel" and "orthogonal" include not only perfectly parallel and orthogonal lines, but also cases where they deviate from parallel and orthogonal lines within an error range.

[0011] Figure 1 is a perspective view showing the structure of the display device 100. Figure 2 is a cross-sectional view showing the structure of the display device 100 along the line A-A' in Figure 1. As shown in Figure 1, a Cartesian coordinate system including the x, y, and z axes is defined. The x and y axes are orthogonal to each other. The z axis is perpendicular to the x and y axes and extends in the vertical direction of the display device 100. The positive direction of the x, y, and z axes is defined in the direction of the arrows in Figure 1, and the negative direction is defined in the direction opposite to the arrows. Here, the positive direction of the x axis may also be called "forward" or "front side", the negative direction of the x axis may be called "backward" or "rear side", the positive direction of the y axis may be called "right" or "right side", the negative direction of the y axis may be called "left" or "left side", the positive direction of the z axis may be called "up" or "upper side", and the negative direction of the z axis may be called "down" or "down side". Therefore, it can be said that the x axis extends in the front-to-back direction, the y axis extends in the left-to-right direction, and the z axis extends in the up-to-down direction.

[0012] A plate-shaped glass lens 110 extending in the y-z plane is arranged on the front surface of the display device 100. The glass lens 110 is a light-transmitting member and is made of glass. Resin may be used instead of glass for the glass lens 110, and the glass lens 110 may also be called a transparent member. The edge (in other words, the peripheral edge) of the glass lens 110 is surrounded by a front frame 120. The entire edge of the glass lens 110 may be surrounded by the front frame 120, or a part of the edge may not be surrounded by the front frame 120. For example, the top edge and the left and right edges of the glass lens 110 may be surrounded by the front frame 120, and another member may be attached to the bottom edge.

[0013] The front frame 120 is positioned on a portion of the front and side surfaces of the display device 100. Behind the front frame 120, the rear frame 130 is positioned to cover the side and rear surfaces of the display device 100. In this way, the side and rear surfaces of the display device 100 are covered by the front frame 120 and the rear frame 130. The front frame 120 and the rear frame 130 are made of resin. A general-purpose resin other than PP is used. General-purpose resins include, for example, PC (Polycarbonate), ABS (Acrylonitrite Butadiene Styrene), and combinations thereof. The front frame 120 corresponds to the aforementioned resin frame.

[0014] Inside the display device 100, which is enclosed by a glass lens 110, a front frame 120, and a rear frame 130, a display panel 200 is positioned opposite the glass lens 110. An example of the display panel 200 is a combination of a liquid crystal panel and a backlight unit. The display panel 200 emits display light from its front toward the glass lens 110. The sides and rear of the display panel 200 are covered by a metal chassis 300. In particular, the rear of the display panel 200 is positioned opposite a flat plate (described later) of the metal chassis 300. The metal chassis 300 is a sheet metal chassis and is made of iron. The front end of the metal chassis 300 is connected to the front frame 120. The front of the front frame 120 is connected to the glass lens 110, and the rear of the front frame 120 is connected to the rear frame 130.

[0015] In the following, Figure 3 will also be used to further explain the structure of Figure 2. Figure 3 is a partially cross-sectional view that is an enlarged portion of Figure 2. Figure 3 shows the upper part of the display device 100, but the lower part, left part, and right part may have a similar structure. The glass lens 110 has a front surface 112 facing forward and a rear surface 114 facing backward. In Figure 3, the display panel 200 attached to the central part of the rear surface 114 of the glass lens 110 is omitted.

[0016] The metal chassis 300 includes a flat plate 310, side walls 320, and frame plate 340, and is integrally formed. The flat plate 310 of the metal chassis 300 has a plate shape that extends in the y-z plane. The central part of the flat plate 310 covers the display panel 200 (not shown) from the rear. If the flat plate 310 has a rectangular shape, the four sides are edges 312 (in other words, peripheral edges). Side walls 320 are provided on the edges 312, extending toward the front. The side walls 320 surround the sides of the display panel 200 (not shown). The foremost part of the side wall 320 is the tip 330, and a frame plate 340 is provided that extends outward from the tip 330. The frame plate 340 has a frame shape in the y-z plane and has an outer edge 342 as its outer edge. In other words, the flat plate 310, the side wall 320, and the frame plate 340 are formed by Z-bending.

[0017] The front frame 120 is attached to the outer edge 342 of the frame plate 340 from the outside. In particular, the front frame 120 is attached to the metal chassis 300 by gripping the frame plate 340 from the outer edge 342. This structure of the front frame 120 and the metal chassis 300 is a chassis insert integrated structure. The chassis insert integrated structure is manufactured by insert molding the front frame 120 and the metal chassis 300.

[0018] Figure 4 is a perspective view showing the structure of the front frame 120 and the metal chassis 300. This is a housing structure in which the front frame 120 in Figures 2 and 3 is attached to the metal chassis 300. The flat plate 310 of the metal chassis 300 has a rectangular shape, and its four sides are shown as the first edge 312a, second edge 312b, third edge 312c, and fourth edge 312d. The first edge 312a extends horizontally on the lower side of the flat plate 310, and the second edge 312b extends vertically on the left side of the flat plate 310. The third edge 312c extends vertically on the right side of the flat plate 310, and the fourth edge 312d extends horizontally on the upper side of the flat plate 310. The fourth edge 312d corresponds to the edge 312 in Figure 3. Furthermore, the first edge portion 312a, the second edge portion 312b, the third edge portion 312c, and the fourth edge portion 312d are collectively referred to as the edge portion 312.

[0019] In the following, Figures 5 and 6 will also be used to further explain the structure of the front frame 120 and the metal chassis 300. These are enlarged partial perspective views of a part of Figure 4, in particular the first edge 312a and the second edge 312b. The third edge 312c and the fourth edge 312d will not be explained, but the third edge 312c is the same as the second edge 312b, and the fourth edge 312d is the same as the first edge 312a.

[0020] The first edge 312a and the second edge 312b are arranged adjacent to each other. A first lateral wall 320a is erected from the first edge 312a, and the first frame plate 340a extends outward from the first tip 330a of the first lateral wall 320a. The outer edge of the first frame plate 340a is the first outer edge 342a, and the end of the first frame plate 340a on the second frame plate 340b side is the first end 344a. A second lateral wall 320b is erected from the second edge 312b, and the second frame plate 340b extends outward from the second tip 330b of the second lateral wall 320b. The outer edge of the second frame plate 340b is the second outer edge 342b, and the end of the second frame plate 340b on the first frame plate 340a side is the second end 344b.

[0021] The first lateral wall 320a and the second lateral wall 320b are collectively referred to as the lateral wall 320, the first tip portion 330a and the second tip portion 330b are collectively referred to as the tip portion 330, and the first frame plate 340a and the second frame plate 340b are collectively referred to as the frame plate 340. In addition, the first outer edge portion 342a and the second outer edge portion 342b are collectively referred to as the outer edge portion 342, and the first end portion 344a and the second end portion 344b are collectively referred to as the end portion 344. The front frame 120 is attached from the outside to the first outer edge portion 342a of the first frame plate 340a and the second outer edge portion 342b of the second frame plate 340b.

[0022] Multiple first anchors 350a are provided on the first outer edge 342a of the first frame plate 340a. Each first anchor 350a has a shape without edges, for example, a hole shape. The multiple first anchors 350a are provided at intervals of D1. On the other hand, multiple first protrusions 122a are provided on the edge of the front frame 120 that is in contact with the first outer edge 342a. The multiple first protrusions 122a are positioned to correspond to the multiple first anchors 350a. Therefore, the multiple first protrusions 122a are also provided at intervals of D1. When the front frame 120 is attached to the metal chassis 300, the multiple first protrusions 122a are combined with the multiple first anchors 350a. Here, D1 is set to, for example, 40 mm or less. This is a value that is below the allowable stress in high and low temperature environments, taking into account the difference in the coefficients of linear expansion between resin and metal, in order to prevent the front frame 120 from being destroyed by deformation due to temperature changes. For example, the results of 3D CAD analysis can be used to determine D1.

[0023] Multiple second anchors 350b are provided on the second outer edge 342b of the second frame plate 340b. Each second anchor 350b has a shape without edges, such as a hole. The multiple second anchors 350b are provided at intervals of D1. On the other hand, multiple second protrusions 122b are provided on the edge of the front frame 120 that is in contact with the second outer edge 342b. The multiple second protrusions 122b are positioned to correspond to the multiple second anchors 350b. Therefore, the multiple second protrusions 122b are also provided at intervals of D1. When the front frame 120 is attached to the metal chassis 300, the multiple second protrusions 122b are combined with the multiple second anchors 350b.

[0024] Of the multiple first anchors 350a provided on the first outer edge 342a of the first frame plate 340a of the metal chassis 300, the first anchor 350a closest to the first end 344a is provided at a position of 7 mm or less from the first end 344a. When the front frame 120 is positioned outside the first frame plate 340a, local stresses are likely to occur. On the other hand, by providing the first anchor 350a at a position of 7 mm or less from the first end 344a, local stresses are less likely to occur.

[0025] Of the multiple second anchors 350b provided on the second outer edge 342b of the second frame plate 340b of the metal chassis 300, the second anchor 350b closest to the second end 344b is provided at a position of 7 mm or less from the second end 344b. When the front frame 120 is positioned outside the second frame plate 340b, local stresses are likely to occur. On the other hand, by providing the second anchor 350b at a position of 7 mm or less from the second end 344b, local stresses are less likely to occur.

[0026] According to this embodiment, multiple anchors 350 are provided at intervals of 40 mm or less, and multiple protrusions 122 are provided at intervals of 40 mm or less. Since the multiple protrusions 122 are combined with the multiple anchors 350, the generation of localized stress can be suppressed in high-temperature or low-temperature environments. Furthermore, since the generation of localized stress is suppressed in high-temperature or low-temperature environments, the occurrence of resin cracking can be suppressed when combining general-purpose resins other than PP with metal. In addition, since the generation of localized stress is suppressed in high-temperature or low-temperature environments, general-purpose resins other than PP can be used in insert molding.

[0027] Furthermore, since a first anchor 350a is provided at a position of 7 mm or less from the first end 344a, and a second anchor 350b is provided at a position of 7 mm or less from the second end 344b, and the first projection 122a is combined with the first anchor 350a, and the second projection 122b is combined with the second anchor 350b, the generation of local stress can be suppressed. In addition, since the generation of local stress is suppressed, the occurrence of resin cracking can be suppressed when general-purpose resins other than PP are combined with metal.

[0028] An outline of one aspect of the present disclosure is as follows: (Item 1) A housing structure comprising: a metal chassis having a flat plate, a lateral wall erected from the edge of the flat plate, and a frame plate extending outward from the tip of the lateral wall; and a resin frame attached from the outside to the outer edge of the frame plate, wherein a plurality of anchors are provided on the outer edge of the frame plate of the metal chassis at intervals of 40 mm or less, and a plurality of protrusions are provided on the resin frame at intervals of 40 mm or less, and when the resin frame is attached to the metal chassis, the plurality of protrusions are combined with the plurality of anchors.

[0029] (Item 2) A metal chassis having a flat plate with adjacent first and second edges, a first lateral wall erected from the first edge, a first frame plate extending outward from the tip of the first lateral wall, a second lateral wall erected from the second edge, and a second frame plate extending outward from the tip of the second lateral wall, a resin frame attached from the outside to the first outer edge of the first frame plate and the second outer edge of the second frame plate, wherein a first anchor is provided on the first outer edge of the first frame plate of the metal chassis at a position of 7 mm or less from the first end of the first frame plate on the second frame plate side, a second anchor is provided on the second outer edge of the second frame plate of the metal chassis at a position of 7 mm or less from the second end of the second frame plate on the first frame plate side, and the resin frame is provided with a first projection and a second projection. In a housing structure in which the resin frame is attached to the metal chassis, the first projection is combined with the first anchor and the second projection is combined with the second anchor.

[0030] (Item 3) A display device comprising the housing structure described in Item 1 or 2, and a display panel having a front surface and a back surface, wherein the back surface of the display panel is positioned opposite the flat plate.

[0031] The present disclosure has been explained above based on examples. These examples are illustrative, and it will be understood by those skilled in the art that various modifications are possible for each component or combination of processing steps, and that such modifications are also within the scope of the present disclosure.

[0032] According to this disclosure, when combining general-purpose resins other than PP with metal, the occurrence of resin cracking can be suppressed.

[0033] 10 Vehicle, 50 Dashboard, 52 Windshield, 54 Steering wheel, 56 Center console, 100 Display device, 110 Glass lens, 112 Front, 114 Rear, 120 Front frame, 122 Protrusion, 130 Rear frame, 200 Display panel, 300 Metal chassis, 310 Flat plate, 312 Edge, 320 Side wall, 330 Front end, 340 Frame plate, 342 Outer edge, 344 End, 350 Anchor.

Claims

1. A housing structure comprising: a metal chassis having a flat plate, a side wall erected from the edge of the flat plate, and a frame plate extending outward from the tip of the side wall; and a resin frame attached from the outside to the outer edge of the frame plate, wherein a plurality of anchors are provided on the outer edge of the frame plate of the metal chassis at intervals of 40 mm or less, and a plurality of protrusions are provided on the resin frame at intervals of 40 mm or less, and the plurality of protrusions are combined with the plurality of anchors.

2. The housing structure according to claim 1, wherein the flat plate, the side wall, and the frame plate are formed by Z-bending.

3. A metal chassis comprising: a flat plate having adjacent first and second edges; a first lateral wall erected from the first edge; a first frame plate extending outward from the tip of the first lateral wall; a second lateral wall erected from the second edge; and a second frame plate extending outward from the tip of the second lateral wall; a resin frame attached from the outside to the first outer edge of the first frame plate and the second outer edge of the second frame plate; a first anchor provided on the first outer edge of the first frame plate of the metal chassis at a position of 7 mm or less from the first end of the first frame plate on the second frame plate side; a second anchor provided on the second outer edge of the second frame plate of the metal chassis at a position of 7 mm or less from the second end of the second frame plate on the first frame plate side; and a first projection and a second projection provided on the resin frame. A housing structure in which the first projection is combined with the first anchor and the second projection is combined with the second anchor.

4. The housing structure according to claim 3, wherein the flat plate, the first side wall, and the first frame plate are formed by Z-bending, and the flat plate, the second side wall, and the second frame plate are formed by Z-bending.

5. The housing structure according to claim 3 or 4, wherein a plurality of first anchors are provided on the first outer edge of the first frame plate of the metal chassis at intervals of 40 mm or less, a plurality of second anchors are provided on the second outer edge of the second frame plate of the metal chassis at intervals of 40 mm or less, a plurality of first protrusions are provided on the resin frame at intervals of 40 mm or less, and a plurality of second protrusions are provided on the resin frame at intervals of 40 mm or less.

6. The housing structure according to any one of claims 1 to 5, wherein the metal chassis is a sheet metal chassis.

7. The housing structure according to any one of claims 1 to 6, wherein the resin frame is made of PC (Polycarbonate), ABS (Acrylonitrite Butadiene Styrene), or a combination thereof.

8. The housing structure according to any one of claims 1 to 7, wherein the metal chassis and the resin frame are insert-molded.

9. The housing structure according to any one of claims 1 to 8, further comprising a rear frame disposed on the rear side of the resin frame.

10. A display device comprising a housing structure according to any one of claims 1 to 9, and a display panel having a front surface and a back surface, wherein the back surface of the display panel is positioned opposite the flat plate.

11. The display device according to claim 10, further comprising a glass lens, wherein the display panel is arranged in the space surrounded by the glass lens and the resin frame.

12. The display device according to claim 11, wherein the display panel emits display light toward the glass lens.

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