Note: Descriptions are shown in the official language in which they were submitted.
1~90522
The present invention relates to a hybrid framework
consisting of a metallic plate and one or more projections
secured thereto. Such frameworks are used ln electrical and
electronic devices such as a tape recorder.
In constructing an electrical or electronic device,
such as a tape recorder or the like, various components incor-
porated therein, for example a printed circuit plate, a trans-
former, a motor or a speaker, are normally spaced from a
chassis or framework therefor by pro~ections fixed to the
surface of the framework. Additionally, other pro~ections may
be provided for use in actuating various mechanisms incorporated
therein. Such latter pro~ections include, for example, a leaf
spring employed in association with a rotary switch unit,
wherein one end portion of the leaf spring is secured to the
framework and the other ent portion thereof urges against a
cam plate of the rotary switch unit so that the cam plate can
be held in any operating position. A pro~ection may also act
as a guide block for reciprocally supporting a movable member,
or as a case block for receiving part of the mechanism therein.
Noreover, if the framework of such a device consists
of several layers, it may be necessary to form suitable openings
in the framework so that the mechanism provided on one layer
may be operated from another layer by arm means mechanically
connecting the mechanisms provided on the two layers through an
opening, or in order that one of the components provided on a
lower layer may be more firmly supported thereon by socketing
the head portion of the component into an opening formed in an
upper layer. For the former purpoge the opening may be provided
with another arm means extending across the opening for sensing
the movement of the first arm means. On the other hand, for
the latter purpose, the opening must be formed with accuracy
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so that the head portion i8 exactly received therein.
Such projections and openings as described above
are formed on or in the framework before the various components
and mechanisms are assembled thereon. Conventionally, the
projections are formed by the methods described hereinbelow.
According to one conventional method, the above
described pro~ections, usually made of synthetic resin such as
thermoplastics, are preliminarily molded into preferable
configurations in an independent process before being mounted
on the framework of an electrical device. During assembly,
each of the pro~ections is placed on the framework at a pre-
determined position, and then fixedly mounted thereon, one by
one, by suitable securing means such as screws, or otherwise
by lnsertion thereof into an opening formed in the framework.
On the other hand, according to another conventional
method which is used in the case where the framework 18 made of
synthetlc resln, the pro~ections may be integrally formed on
the framework during the molding step.
However, the above described conventlonal methods
hltherto employed to form projections on the framework have
numerous disadvantages as descrlbed herelnbelow.
In the former method, it is necessary to keep a
number of each kind of pro~ection for mounting on the framework,
and also the projections must be prepared in a separate step.
Thus, two processes are necessary which results in an increase
of the manufacturing cost for the device, as compared with a
proce~s which requires only a single constructlng step.
In the latter method, although the above de~crlbed
two steps, i.e., the step of producing the pro~ectiong and
the step of mounting them on the framework, are avolded, the
pro~ections may not be formet at predetermined positions with
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accuracy, due to the fact that the distortion of the synthetic
resin may deform the projections undesirably, or that uneven
shrinkage of the synthetic resin may direct the projections in
unpredictable directions. Furthermore, a framework made of
synthetic resin is not suitable for large devices, especially
when the framework is of thin-gauge because the lack of stiff-
ness of the synthetic resin may result in insufficient strength
to support the components to be contained therein, and also
the larger the mass of the synthetic resin becomes, the greater
the distortion will be, due to shrinkage.
Therefore, it is a primary ob~ect of the present
invention to improve the construction of an electrical device
or mechanical device by molding synthetic resin parts directly
onto a metallic framework therefor.
According to the invention there is provided a hybrid
framework assembly for use in electrical or mechanical devices
as a substratum and capable of being formed by a process of
in~ection molding, and for supporting various components
incorporated in said devices, said hybrid framework assembly
comprising; a. a metallic base having opposite surfaces and at
least one opening therein between said surfaces; b. at least
one pro~ection on said metallic base plate and made of synthetic
regin and having a base face thereof attached to sa~d metallic
base plate on a first of said surfaces of said metallic base
plate ad~acent said opening and being larger than said opening
and having a portion of said proiection extending over said
opening, said projection having a constricted portion integrally
formed therewith extending into snd through said opening,
snd a lump of synthetic resin on the second of said 8urfaces
of said metallic base plate and integrally formed with said
constricted portion, said lump of synthetic resin at least
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partially covering said opening for tightly holding said
pro~ection permanently on said metallic base plate.
Before molding the synthetic resin parts onto the
framework, the metallic framework must be formed with openings
at predetermined positions, and then each of these openings i8
completely surrounded by the walls of a cavity formed between
two molting blocks which hold the framework therebetween. One
of the blocks, which faces the upper surface of the framework
where the projections must be formed, has a recess having the
shape of the desired pro~ection, and the other block, which
faces the opposite surface, has a shallow recess at a positlon
corresponding to the first recess formed in the other block.
When these two blocks tightly hold the framework,
therebetween, the recess formed in the upper block and the
corresponding recess formed in the lower block form a cavity
having two parts connected through the opening formed in the
framework.
The cavity formed by the two blocks is then filled
with plasticized synthetic resin by any known means such as by
a plastic in~ection-molding machine. When the product in the
cavity is hardened by cooling and the mold block is opened, the
product ejected therefrom is securely fixed to the metallic
framework. In other words, the ejected product tightly grips
the edge of the opening formed in the metallic framework
because the pro~ection and the integral synthetic resin member
formed on the other side of the framework act together to grip
the framework as in riveting due to the shrinkage of the
synthetic resin.
Although it ls possible to inst811 a pro~ection ln
the manner stated us$ng one or two circular openings formed in
the framework, especially when the pro~ection i8 snall, when
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the projectlon is large, such as when the pro~ection is to be
used as a ca*e block, it may be difficult to secure the pro-
jection sufficiently firmly on the framework. However, on the
other hand, if such a large projection were to be held on the
framework by several openings, the shrinkage of the synthetic
resin might cause the pro~ection to undergo distortion, since
the shrinkage normally proceeds towards the center portion of
the product.
In the present invention, a large projection can be
installed over an opening having a number of grooves formed on
the framework radially extending outwardly from the center
portion of the opening, thus the bottom portion of the product
may shrink towards the center portion thereof in relation to
the other portions thereof, and as a result, the whole product
may shrink evenly.
Although the pro~ections in the foregoing description
are formed individually it is possible, in the present invention,
to form a plurality of synthetic resin pro~ections simultaneously
in a single molding operation by connecting the cavities with
2~ channels or grooves forming runners. Each cavity serves as a
mold for a single item, i.e., the spacer pro~ection the guiding
pro~ection, the leaf spring, etc. Although the small ite~s
themselves may not shrink to such a degree as to distort the
original configuration thereof, the shrinkage of the runners
connecting the items may undesirably enforce the items to
incline or rotate. Therefore, according to the present inven-
tion, these runners are provided with further auxiliary runners
for forcibly preventing such undesirable distortions, or other-
wi6e the runners are molded in such a way that the shrinkage
does not cause the items to be distorted.
Since the runners are provided only for connecting
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the cavities during molding, they may be removed after being
ejected from the mold. However, such an operation to remove
the runners may be unnecessary if the runners do not adversely
affect the component or mechanism to be incorporated in the
device. Those runners which might affect a component or
mechanism may be formed in such a manner as to detour the
component or mechanism and so be spaced therefrom.
Preferred embodiments of the invention are described
in the following with reference to the accompanying drawings,
in which:
Fig. 1 is a perspective view of a completed frame-
work F;
Fig. 2 is a top plan view of the framework F shown
in Fig. l;
Fig. 3 is a bottom view of the framework F shown in
Fig. l;
Fig. 4 is a cross sectional view taken along the
line IV-IV of Fig. 2;
Fig. 5 is a top plan view of the base plate B;
20Fig. 6 is a schematic side view of the base plate B
together with the upper and lower molding blocks Ml and M2;
Fig~. 7 and 8 are fragmen~ary front and top views
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of the inverted L-shaped projection;
Fig. 9 is a cross sectional view taken along the line
IX-IX of Fig. 8;
Fig. 10 is a fragmentary top plan view of the base
plate before forming the inverted L-shaped projection thereon;
Fig. 11 is a fragmentary cross sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the inverted L-shaped projection;
Fig. 12 is a fragmentary exploded view of the
framework F, showing a part of mechanism coupled with the leaf
spring;
Figs. 13 and 14 are fragmentary cross sectional views
of the base plate, showing the openings to be formed in the
base plate for forming the leaf spring together with the cut
out pieces;
Fig. 15 is a fragmentary cross sectional view of
; the base plate for forming the leaf spring, and showing the
relation between the upper and lower molding blocks;
Fig. 16 is a fragmentary side sectional view of
the ejected leaf spring;
Fig. 17 is a similar view to Fig. 16, but particularly
shows the ejected leaf spring after the cut out piece i8 re ved;
Figs. 18 and 19 are fragmentary top and front views
of a series of guiding blocks;
Fig. 20 is a perspective view of one of the series of
guiding blocks;
Fig. 21 is a fragmentary top plane view of the base
plate for forming thereon a series of guiding blocks, shown in
Figs. 18 and 19;
Fig. 22 is a fragmentary side sectional view showing
the relation between base plate and the upper and lower molding
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..,
blOcks, for forming the series of guiding blocks;
Fig. 23 is a similar view to Fig. 19, but particularly
shows a modification thereof:
Figs. 24 and 25 are fragmentary explanatory diagrams
for the series of guiding blocks shown in Figs. 18 to 23;
Figs. 26 and 27 are similar views to Figs. 18 and 19,
but particularly show a modification thereof;
Fig. 28 is a-side view of the series of guiding blocks
shown in Fig. 27;
Fig. 29 is a perspective view of one of the guiding
blocks shown in Figs. 26 to 28;
Fig. 30 is a fragmentary top plan view of the base
plate for forming series of guiding blocks shown in Figs.
26 to 28;
Fig. 31 is a fragmentary side sectional view of
the series of guiding blocks shown in Figs. 26 to 28, showing
the relation between the upper and lower molding blocks;
Fig. 32 ls an explanatory diagram for the series
of guidlng blocks shown in Figs. 26 to 28;
Fig. 33 is a similar view to Fig. 26, but particularly
shows a modification thereof,
Figs. 34 to 36 are similar views to Figs. 26 to 28,
but particularly show a modification thereof;
Fig. 37 is an exploded view of the guiding blocks
shown in Figs. 34 to 36, showing a part of mechanism to be
coupled with the guiding blocks;
Fig. 38 is a fragmentary perspective view of a
U-shaped leaf spring together with accessory parts therefor
installed on the base plate;
Fig. 39 is a fragmentary top plane view of the base
plate showing openings for forming the U-shaped leaf spring
and accessory parts therefor;
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Fig. 40 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the U-shaped leaf spring and accessory
parts therefor;
Fig. 41 is a schematic sectional view of the ejected
U-shaped leaf spring and accessory parts therefor;
Fig. 42 is a fragmentary top plan view of the u-shaped
leaf spring and accessory parts therefor showing a part of
mechanism coupled therewith;
Fig. 43 is a fragmentary top plan view of a case
projection,
Pig. 44 is a cross sectional view taken along the
line X-X of Fig. 43;
Fig. 45 is a fragmentary top plan view of the base
plate showing an opening for forming the case projection shown
in Fig. 43;
Fig. 46 is a side sectional view showing the relation
between the base plate and the upper and lower molding ~locks
for forming the case projectlon shown in Fig. 43;
Figs. 47 and 48 are explanatory diagrams for the
case projection shown in Fig. 43;
Fig. 49 is a similar view of Fig. 43, but particularly
shows a modification thereof;
Fig. 50 is a cross sectional view taken along the
line L-L of Fig. 49;
Fig. 51 is a similar view to Fig. 45, but particularly
shows a modification thereof;
Fig. 52 is a similar view to Fig. 51, but particularly
shows a detailed construction thereof in an enlarged scale;
Figs. 53 and 54 are fragmentary top and front views
of runners connecting two boss projections;
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Fig. 55 is a fragmentary top plan view of the base
plate showing openings for forming the boss projections shown
in Figs. 53 and 54;
Fig. 56 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the boss projections together with
the runners shown in Figs. 53 and 54;
Fig. 57 is a diagram explanatory of the runner connect-
ing the two boss projections;
Figs. 58 and 59 are fragmentary top and front views
of a runner connecting two boss projections;
Fig. 60 is a fragmentary top plan view of the base
plate showing opening for forming the boss projections shown
in Figs. 58 and 59;
Fig. 61 is a fragmentary cross sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the boss projections together with
the runner shown in Figs. 58 and 59;
Flg. 62 is a simllar view ~ Fig. 58, but~,particularly
shows a mGdificatlon thereof;
Figs. 63 and 64 are similar views to Figs. 58 and 59,
but particularly show a modification thereof;
Fig. 65 is a fragmentary top plan view of the base
plate showing openings for forming the boss projection shown
in Figs. 63 and 64;
Fig. 66 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
lding blocks for forming the boss projection together with
the runner shown in Figs. 63 and 64;
Figs. 67 and 68 are similar views to Figs. 58 and 59,
but particularly show a modification thereof;
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Fig. 69 is a fragmentary top plan view of the base
plate showing openings for forming the two boss projections and
runner shown in Figs. 67 and 68;
Fig. 70 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the boss projection together with
the runner shown in Figs. 67 and 68;
Figs. 71 and 72 are fragmentary top and front views
of a L-shaped runner connnecting the boss projections;
Fig. 73 is a fragmentary top plan view of the base
plate showing openings for forming the two boss projections
and the L-shaped runner shown in Figs. 71 and 72;
Fig. 74 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the boss projection together with
the L-shaped runner shown in Figs. 70 and 72;
Fig. 7~ is a diagram explanatory of the L-shaped runner
shown ~n Figs. 70 and 71;
Fig.76 is a fragmentary side elevational view of a
runner connecting the two boss projections;
Fig. 77 is a fragmentary side sectional view of a
runner showing a detailed construction thereof;
Fig. 78 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the boss projection together with
the runner shown in Fig. 76;
Fig. 79 is a fragmentary top plan view of the base
plate showing openings for forming the two boss projections
and the runner shown in F~g. 76;
Fig. 80 is a fragmentary top plan view of the base
plate formed with the boss projection and runner shown in
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Fig. 76, and also provided with the composing elements for the
framework;
Fig. 81 is a fragmentary top plan view of a runner
connecting the two boss projections;
Fig. 82 is a cross sectional view taken along the
line XV-XV in Fig. 81,
Fig. 83 is a fragmentary top plan view of the base
plate showing openings for forming the boss projections together
with the runner shown in Fig. 81;
Fig. 84 is a fragmentary side sectional view showing
the relation between the base plate and the upper and lower
molding blocks for forming the boss projections and the runner
shown in Fig. 81; and
Fig. 85 is a similar view to Fig. 83, but particularly
shows a modification thereof.
Referring to Figs. 1 to 4, there is shown a completed
piece of a framework F for use in a device, for example, a
tape recorder, which comprises a metallic base plate B and a
plurality of synthetic resin products which are generally
called projections P, and fixedly mounted on the base plate B
for holding components (not shown) to be incorporated in the
device or for actuating the mechanism incorporated in the device.
These projections P made of synthetic resin such as polyacetal,
are formed by a process of injection molding which forms a
plurality of projections at a time, so that one molding process
may produce a plurality of projections P fixedly formed on the
base plate B.
In order to form such projections P on the base
plate B, the base plate 8 i5 preliminarily provided with
openings at the positions where the projections P are to be
formed as shown in Fig. 5. Detailed description for each of
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the openings are described later in connection with thedescription for each of the projections P. The base plate B
with the openings are then held between upper and lower molding
blocks Ml and M2. For the purpose of convenience, the pair
of upper and lower molding blocks Ml and M2 may be divided into
several pairs. The upper molding block Ml is provided with
recesses each of which correspond with the configuration of
each projection P. On the other hand, the lower molding block
is provided with shallow recesses at corresponding position
to the recesses formed in the upper molding block for forming a
lump of synthetic resin thereat. When the upper and lower
molding blocks Ml and M2 tightly hold the base plate B there-
between, each of the recesses formed in the upper molding block
Ml and corresponding recesses formed in the lower molding
block M2 form a cavity through the opening formed in the base
plate B. The positioning of the base plate B between the molding
blocks Ml and M2 is achieved by at least two pins N integrally
formed on the lower molding block M2, each of the pins N being
introduced into corresponding opening W, formed in the base
plate B, as most clearly seen in Fig. 6. Normally on the lower
molding block, the shallow recesses are connected to each other
by grooves, which forms channels, namely runners when the base
plate B is held between the molding blocks. The molten synthetic
resin is injected into the cavities from at least one cavity
gate. In this case, these cavity gates lnot shown) are formed
in the lower molding block M2. The reference characters Gl,
G2 and G3 in Fig. 3 show the positions from which the molten
synthetic resin is injected.
Therefore, as a result, each projection P substantially
has an extending portion inserted into the opening which is
formed in the base plate B, and a lump of synthetic resin
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integrally formed with the extending portion immediately belowthe plate B in such a manner to cover up the above mentioned
opening.
It should be noted that the recess formed in the lower
molding block Ml can be provided with a projection for the
purpose of present invention, which will be described in detail
in connection with Figs. 7 to 11.
According to the present invention, those projections
are formed in the process of molding by proceeding the following
four steps:
a first step is mating the upper molding block Ml
with the upper mating surface of the base plate B, and the lower
molding block M with the lower mating surface of the base plate
B, thus forming cavities by the two molding blocks;
: a second step is injecting molten synthetic resin into
the cavities from the cavity gate with any known injection
m~chine;
a third step is cooling the molding blocks and
further injected synthetic resin to solidify the latter; and
a fourth step is ejecting the synthetic resin
products formed by the molding engaged with the base plate B.
After having completed these molding steps, each
of the projections P formed by the mold is fixedly installed
on the base plate B because each projection formed on the
upper surface of the base plate B and the integrally formed
lump of synthetic resin on the lower surface of the base
plate B tightly holds the edge of the opening by the effect
of shrinkage caused in the synthetic resin in the opening.
Therefore, projections ejected from the mold can be
readily used as projections for holding various components or
for effecting the mechanism incorporated therein.
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Referring particularly to Fig. 2, each of the items1 through 14 encircled by a chain line composes units of the
framework F, wherein the numerals 1 through 7 designate indivi-
dual projections P, while the numerals 8 through 14 designate
various runner means which connect two individual projections.
The detailed description for each of the items 1
through 14 are given individually in connection with the
attached drawings hereinafter.
ITEM 1
Referring to Figs. 7 to 9, there is shown a completed
piece of the molded projection P, namely in inverted L-shaped
projection 21, installed on the base plate B, while an opening
22 is formed immediately next to the L-shaped projection 21.
The L-shaped projection 21, extending upwardly at right angles
from the base plate B, is bent at upper portion thereof to cover
part of the opening 22. Positioned under the base plate B is
a lump 23 of synthetic resin, integrally formed with the
inverted L-shaped projection 21 through a small opening 24
formed in the base plate B. Since the size of the lump 23 is
greater than that of the small opening 24, the L-shaped projec-
tion 21 is fixedly secured to the base plate B. The peripheral
edge of the opening 22 is provided with a frame 25 which
is also formed by the molding.
The opening 22 is adapted to receive therein, for
instance, a head portion 26 of one of the components as shown
in a chain line in Fig. 7 and, incorporated below the base
plate B, while the L-shaped projection 21 is adapted to engage
said head portion 26 inserted into the opening 22 in a position
adjacent to the upper bent over portlon.
In order to form such L-shaped projection 21 together
with the frame 25 for the opening 22, the metallic base plate
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B is preliminarily formed with openings 22 and 24, as most
clearly seen in Fig. 10. It should be noted that the opening
22 ls larger than the opening 24. Then, the base plate B is
tightly held between upper and lower molding block Ml and M2,
as shown in Fi~. 11. The upper molding block Ml has a recess
27 which corresponds with the configuration of the inverted
L-shaped projection 21 engaging with above described head
portion 26. On the other hand, the lower molding block M2
has a shallow recess 28 which corresponds with the lump 23,
and also has a projection 29 extending upwardly from a position
immediately next to the shallow recess 28. The projection 29
has a size exactly the same as that of the above described head
portion 26. The shallow recess 28 is connected by a groove
30 extending towards one of the neighboring shallow recess
(not shown). When these two molding blocks Ml and M2 tightly
hold the base plate B therebetween in corresponding position,
the cavity formed by the recesses 27 and 28 has exactly the same
configuration as the ~-shaped projection 21 together with the
lump 23.
It should be noted that the projection 29 should
not contact any portion of the edges of the opening 26, but
should loosely pass through the opening 26, thereby forming
a part of cavity between the edge of the opening 26 and the
surface of the projection 29.
When the molten synthetic resin is injected into the
cavity by any known injection means from a cavity gate (not
shown), the molten synthetic resin fills up the cavity.
Su~sequently, the molding blocks Ml and M2 are cooled by a
suitable cooling means (not shown) to solidify the synthetic
resin injected therein. Soon after synthetic resin solidifies,
the mold is opened and the finished piece of the projection
21 is ejected with the lump 23 fixedly holding the opening
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24 of the base plate B as in riveting, as best shown in Fig. 9.
Since parts of the cavity existed around the edge ofthe opening 26, the opening 22 is provided with the synthetic
resin frame 25 when ejected from the mold, thus forming a smaller
opening 22, which must be formed with an accuracy so as to
receive the above described head portion 26 therein.
Although it is possible to obtain the opening 22 with-
out forming any frame therearound, by preliminarily forming
an opening 22' (not shown) in the metallic plate B ~the
opening 22' is an imaginary opening formed in the base plate B
and substantially equal to the opening 22), the projection
29 must fit exactly in the opening 22' for preventing any molten
synthetic resin to flow between the opening 22' and the project-
ion 29, in which case the size of the projection 29 must be
finished with accuracy, as well as the opening 22'.
In other words, in order to prevent the synthetic
resin to flow therethrough, the size of the projection 29 on
the molding block M2 must be formed with accuracy as well as
the opening 22', and yet the insertion of the projection 29
may be carried out with much difficulty.
On the other hand, according to the present invention,
the opening 22 can be formed precisely in the predetermined size
by the frame 25 in the step of molding, at the position around
the edge of the previously prepared opening 22 in the metallic
base plate B. In this case, the opening 22 is required at least
to be large enough for enabling the proiection 29 to pass
therethrough, and furthermore the positioning of the opening
22 exactly in the predetermined position can be easily effected
by the maintenance of the base plate B between the molding
blocks Ml and M2, which maintenance can be ensured without
difficulty.
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1090S22
Therefore, according to the present invention, the
supporting projection 29 can readily be provided on the metallic
base plate B in the molding process for molding the projection 21,
and still the opening 22 for receiving the head portion can
also be formed with accuracy during the molding process.
ITEM 2
Referring to Fig. 12, there is shown a completed piece
of the molded projection P, namely a leaf spring 31 installed
on the metallic base plate B at one end portion 32 thereof,
10 while the other end portion 33 thereof is extended to cover
part of a rectangular opening 34 formed on the base plate B.
The end portion 33 partly crosses over the opening 34 which
ls provided for receiving an arm means 35 extending from another
base plate B' positioned below the former base plate B in
parallel relation to each other. The arm means 35 is normally
urged towards one direction so that the arm means 35 can be
maintained in one operating position, which position will
actuate one of the mechanism contained therein. Since the
present invention is not directed to the mechanism, detailed
20 descrlption on the operation of the arm means 35 with the
leaf spring 31 is omitted.
In order to form such leaf spring 31 on the base
plate B, with one end portion 33 partly crossing over the
opening 34j the base plate B is preliminarily formed with
openings 34 and 36 as most clearly seen in Fig. 13. At least
the opening 34 is formed by a process of blanking, so that
a blanked out piece 37 can temporarily fill in the opening 34,
as shown in Fig. 14. Then,the base plate B with the blanked
out piece temporarily held in the opening 34 is tightly held
30 between the upper and lower molding blocks Ml and M2.
Referring now to Fig. 15, the upper molding block M
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has a recess 38 which corresponds exactly with the configuration
of the leaf spring 31, while the lower molding block M2 has a
shallow recess 39 formed below the opening 36 for forming a
lump 40 of synthetic resin thereat. It should be noted that the
size of the recess 39 is larger than that of the opening 36.
The lower molding block M2 is further formed with a groove 41
for forming a runner 42, with one end portion thereof connected
to the recess 39 and the other end portion thereof (not shown)
connected to one of the neighboring recess (not shown). After
effecting the molding process in the manner as described above,
the ejected piece, i.e., the leaf spring 31, is fixedly provided
on the base plate B, because the lump 40 integrally connected
with the leaf spring 31 through the opening 36 tightly engages
the opening 36 due to the shrinkage of the synthetic resin in
the opening 36.
Referring to Figs. 16 and 17, the blanked out piece
37 is taken out from the opening 34 to have one end portion
33 of the leaf spring 31 partly crossing over the opening 34.
It should be noted that the leaf spr~ng 31 described
aR partly crossing over the opening 34 can be replaced by any
other projections which can be formed by molding, with respect
to the mechanism to be employed in the device.
It should also be noted that the leaf spring 31 or
any other projections describe as partly crossing over the
opening 34 can be formed so as to completely cross over the
opening 34.
It should further be noted that the opening 34
described as having a rectanqular shape can be formed in any
other configurations such as an elongated groove or a circle,
depending on the type of constructing components or mechanism
to be incorporated in the device.
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Therefore, according to the present invention, thesynthetic resin projection can be extended along the base plate
to cross over the opening formed on the base plate without
any difficulty.
ITEM 3
Referring to Figs. 18 and 19, there is shown completed
pieces of the molded projections P, namely a series of three
guiding blocks 45, 46 and 47 fixedly mounted on the base plate B~
Referring to Fig. 20, each of the U-shaped guiding
blocks has a groove 48 formed by two side projections 49 and
50. These three U-shaped guiding blocks 45, 46 and 47 are
arranged in a straight row, spaced in a predetermined pitch
from each other, in such a manner that respective grooves 48
of these three U-shaped blocks are in alignment with each other,
so that these groo~es 48 may serve to slidingly support the
strip-like sliding member 51 thereon for actuating one of the
mechanism (not shown) employed in the device. These three
U-shaped guidng blocks 45, 46 and 47 are fixedly installed on
the base plate B by lumps 52,53 and 54 formed i ediately below
the base plate B, respectively at positions opposing the guiding
blocks 45, 46 and 47. These lumps 52, 53 and 54 are connected
to each other by runners 55 and 56.
It should be noted that one of the lumps 52, 53 and 54,
for instance, in this case the lump 54, is further connected with
a runner 57 which leads to one of ne~ghboring lump (not shown).
In order to form such series of guiding blocks 45,
46 and 47 fixedly on the base plate B, the metallic base plate
B is preliminarily formed with pairs of openings 58a, 58b,
59a, S9b, 60a and 60b as shown in Fig. 21. Each of the pairs
is located at corresponding position with each of the guiding
blocks to be positioned. Then the metallic base plate B is
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, ~090SZ2
held between the upper and lower molding blocks ~1 and M2.
Referring to Fig.22, the upper molding block Mlhas three recesses 61, 62 and 63 in alignment with each other,
wherein each of the recesses corresponds with the configuration
of the guiding block. The lower molding block M2 has three
shallow recesses 64, 65 and 66 in corresponding position with
the three recesses in the upper molding block for forming the
lumps 52, 53 and 54 of synthetic resin thereat. It should be
noted that each of the shallow recess formed in the lower molding
block M2 has the size large enough to cover the pair of openings
formed in the base plate B.
In addition to three shallow recesses the lower molding
block M2 has two grooves 6~7 and 68 for connecting the three
shallow recesses, and one groove 69 extending from one of the
shallow recess, for instance, in this case the shallow recess 66,
towards one of the neighboring recess (not shown) for another
projection.
When these upper and lower molding blocks Nl and M2
tightly hold the base plate B therebetween a cavity is formed
around each of the pairs oi openings, while each cavity is
connected by the grooves 67 and 68. Then it is ready for
molding.
After effecting the molding process in the same manner
as described abo~e, the ejected pieces, i.e., the series of
guiding blocks 45, 46 and 47 are fixedly provided on the base
plate, because each oi the lumps 52, 53 and 54 integrally connect-
ed to each of the guiding blocks 45, 46 and 47 through the pair
of openings 58a, 58b, 59a, S9b, 60a and 60b, tightly engages
the base plate B, due to the shrinkage of synthetic resin in
the pair of openings.
It should be noted that the series of guiding blocks
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` 10905~2
mentioned above as formed separately on the base plate B can befurther formed with comparatively thin-gauged connecting member
70 and 71 in the spaces formed between the three guiding blocks
for connecting each of the guiding blocks integrally, as shown
in Fig. 23.
It should also be noted that the series of guiding
blocks mentioned above as consisting of three separate guiding
blocks can be consisting of more than three, or even two.
Since the relative positioning of the guiding blocks
45, 46 and 47 is exactly determined by the recesses 61, 62 and
63 formed in the upper molding block, it is not necessary to
adjust each of the guiding blocks 45, 46 and 47 in its predeter-
mined position after having been ejected from the mold, provided
that the recesses 61, 62 and 63 are preliminarily formed with
accuracy.
Although it is possible to form the guiding blocks
in one integral elongated body 72, as shown in Fig. 24, such
gulding block is only suitable for the guiding blocks in small
sizes, which do not need to take the shrinkage of the synthetic
resin ln consideration. However, when the size of the guiding
block becomes comparatively large, the shrinkage of synthetic
resin may cause the metallic base plate B to curve inwardly
together with the guiding block through aplurality of engaged
points between the guiding block and the base plate, as shown
in Fig. 25. Thus, it is preferable to form the guiding blocks
in several pieces.
Therefore, according to the present invention, the
elongated groove formed by the guiding blocks can be maintained
with accuracy, because the shrinking degree of synthetic resin
of each guiding block is not so large as to deform the con-
figuration of the guiding block, and also the relative posi-
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1090522
tioning between the blocks is precisely defined by the moldingblocks which are preliminarily prepared with accuracy.
ITEM 4
-
Referring to Figs. 34 to 37, there is shown a completed
piece of the molded projection P, which is a modification of the
series of guiding blocks 45, 46 and 47 described in the Item 3.
Instead of the three separate guiding blocks described as employed
in the series of guiding blocks in Item 3, the series of guiding
blocks in this Item 4 composed of eight pieces of upright blocks.
Before going into the detailed description for the
series of eight guiding blocks shown in Figs. 34 to 37, first,
the series of six guiding blocks is described in connection with
Figs. 26 to 33, for its more fundamental construction.
Referring to Figs. 26 to 27, there is shown the series
of guiding blocks which are composed of six pieces of L-shaped
blocks 75, 76, 77, 78, 79 and 80. Each of the L-shaped blocks
has a ~eating surface 81 and an upright surface 82, as best
shown 1n Fig. 29.
A first group of three of the six L-shaped blocks 76,
78 and 80 are arranged in a straight row, spaced a predetermined
pitch from each other, in such a manner that respective upright
faces 82 of these three L-shaped blocks 76, 78, and 80 of said
first group face in the same direction and lay on the same
imaginary plane E perpendicular to the base plate B. On the
other hand, a second group of the rest of the six L-shaped
blocks 75, 77, and 79 are arranged in a substantially similar
manner to those of said first group, but have their upright
faces 82 facing in the direction oppposed to the facing
direction of those of the first group and lay on the same
imaginary plane F which is spaced in parallel relation to said
first mentioned imaginary plane E. These first and second
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90522
groups of the L-shaped blocks are oppositely displaced a distance
approximately equal to half the pitch in the direction of the
straight row of any of said first and second groups. The seating
surfaces 81 of the L-shaped blocks of the first and second groups
are disposed in a space defined between the two imaginary planes
E and F, laying on the imaginary plane G perpendicular to any
of said two imaginary planes E and F and parallel to the plane
of the base plate, and upwardly oriented in a direction opposite
to the base plate B.
Therefore, the space defined by the imaginary planes
E, F and G form an elongated groove 83 while the upright surface
82 and.seating surfaces 81 of the blocks of the first and second
groups serve to alternately support the strip-like slidable
plate member 84 thereon as described in connection with Item 3.
Positioned under the L-shaped blocks 75, 76,77, 78,
79, and 80 are respectively lumps 85, 86, 87, 88, 89 and 90 of
synthetic resin, integrally formed with each of the L-shaped
blocks through a pair of openings formed in the base plate.
The size of each lump is larger than that of the pair of
openings, so that each L-shaped block is fixedly installed on
the base plate B. It should be noted that these lumps 85, 86,
87, 88, 89 and 90 are connected to each other by runners 135,
136, 137, 138 and 139, and also the lump 90 is further connected
to the neighboring lump (not shown) by a runner 91.
In order to form such series of guiding blocks 75 to
80, the metallic base plate B is preliminarily f ormed with
pairs of openings 92, 93, 94, 95, 96 and 97 at corresponding
positions with each of the L-shaped blocks 75, 76, 77, 78, 79 and
80 as shown in Fig. 30. Then, the base plate ~ is tightly
held between upper and lower molding blocks Ml and M2, as best
shown in Fig. 31. The upper-molding block Ml has recesses 98,
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lO905ZZ
99, 100, 101, 102 and 103 with the shape thereof correspondingwith the configuration of the series of the L-shaped blocks,
while the lower molding block N2 has shallow recesses 104, 105,
106, 107, 108 and 109 with the shape thereof corresponding
with those of the lumps to be formed under each of the L-shaped
blocks. The lower molding block M2 is further provided with
grooves 110, 111, 112, 113 and 114 which connect each of the
shallow recesses, and also one of the shallow recesses, in
this case the shallow recess 109, is provided with a groove
; 115 which connects one of the neighboring shallow recesses
(not shown) for the pass of synthetic resin.
After effecting the molding process in the same
manner as described above, the ejected pieces, i.e., the
series of L-shaped guiding blocks are fixedly provided on
the base plate B, because each of the lumps 85 to 90 being
integrally connected to each of the L-shaped guiding blocks
through the pair of openings 92 to 97, tightly engages the
base plate B due to the shrinkage of synthetic resin in the
openlngs.
It should be noted that the L-shaped blocks described
as composed of six pieces can be composed of any number of
pieces more than three.
Referring to Fig. 33, there is shown a modification
of the series of guiding blocks. In this embodiment, either
one of the two groups described as being composed of three
pieces of the L-shaped guidingblocks, for example, the three
L-shaped blocks 75, 77 and 79 in the second group can be
replaced by three pieces of blocks 116, 117 and 118 each
having a configuration of rectangular parallelpiped block,
wherein one of the surface is laid on the imaginary plane
and yet the effect is the same as in the former embodiment.
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109052Z
It should be noted that the series of guiding blocks
described as composed of L-shaped blocks, can all be composed
blocks having a configuration of rectangularly parallelpiped
block, wherein the blocks in the first and second groups have
their one surface being laid on the imaginary plane E and F,
respectively, while the imaginary surface G is defined by the
surface of the base plate B, thus the plate member is supported
directly on the base plate B. In this case, the bloc~s in the
first and second groups can either be arranged in above described
manner or in such a manner to have the surfaces defining the
imaginary surfaces E and F ln directly opposing positions.
Referring now to Figs. 34 to 36, the series of eight
guiding blocks are composed of seven blocks ll9 to 125, alter-
nately disposed on the imaginary surfaces F and E, and an end
block 126 disposed adjacent to the block 125. The end block
126 is formed with cut off portion 127 in which the imaginary
plane E and F terminates their edges.
Therefore, the space defined by the imaginary planes
E,F and the surface of the base plate B form an elongated groove
128, while the cut off portion 127 defines the end of the
groove 128. In this groove 128, the slidable plate member
84 can be reciprocally supported, as described above.
Referring to Fig. 37, the block 119 and the end block
127 are formed with a screw hole 129 at top surface thereof for
rigidly securing a plate 130 over the groove;,l28 After placing
the slidable plate member 84 coupled with push buttons 131, 132,
133 and 134 into the groove 128, the plate 130 covers over the
groove 128 for preventing the slidable plate member 84 from being
thrown out from the groove 128.
^ These series of guiding blocks is suitable especially
for supporting sliding plate member with wide width.
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- lO905Z2
Assuming if the series of U-shaped guiding blocks
described in Item 3 were to support such a plate member having
a wide width,each of the U-shaped blocks have to be prepared
with comparatively high side projections, for preventing the
plate member to fall over from the groove. However, such a
U-shaped guiding block with high side projection results in
comparatively great degree of shrinkage, which will deform
the configuration of the U-shaped block in such a manner that
the side projection thereof may curve inwardly toward each
other, as shown in Fig. 32. Therefore, the side projections
may not keep the space between the side projection for
supporting the plate member in even width along the side
projection.
On the other hand, according to the guiding blocks
in Item 4, the space for supporting the plate member is deflned
by the upright surface of thé each L-shaped block. Since
these L-shaped blocks are formed individually, the shrinkage
take place in a direction along the upright surface. Therefore,
according to the guiding blocks of the present invention, the
space for supporting the plate member is maintained evenly
along the upright surface.
ITEM 5
Referring to Fig. 38, there is shown a completed piece
of the molded projection namely a U-shaped leaf spring 140
with accessory parts which are fixedly provided on the metallic
base plate B. One end portion 141 of the U-shaped leaf spring
140 is fixedly provided on the base plate B, while the other
end portion 142 of the U-shaped leaf qpring 140 is free from
the base plate B, thus urging towards one of the component
contained in the device. Adjacent to the free end portion 142
of the U-shaped leaf spring 140 is a pin projection 143 for
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iO90522
receiving said one of the components thereon, and adjacent to thepin projection is an engaging projection 144.
In order to form such projections, the metallic base
plate B is preliminarily formed with openings 145, 146 and 147,
as shown in Fig. 39. Then, the metallic base plate ~ is tightly
held between the upper and lower molding blocks Ml and M2, as
shown in Fig. 40. The upper molding block Ml has three recesses
148, 149 and 150, which correspond with the configuration of the
U-shaped leaf spring 140, the pin projection 143, and the engaging
projection 144. On the other hand, the lower molding block
M2 has three shallow recesses 151, 152 and 153, formed immedi-
ately below the openings 145, 146 and 147, for forming lumps
154, 155 and 156 of synthe*ic resin thereat as best shown in
Fig. 41. It should be noted that the size of the shallow
recesses 151, 152 and 153 are larger than that of the openings
145, 146 and 147, respectively. The lower molding block Ml
is further formed with a grooves 157, 158 and 159 extending
from the shallow recess 152. The grooves 157 and 158 are
connected to the shallow recesses 151 and 153, while the
groove 159 is connected to one of the neighboring shallow
recess (not shown). After effecting the molding process as in
the manner described above, the ejected piece, i.e., the U-shaped
leaf spring 140 with accessory parts, are f ixedly provided on
the metallic plate B, ln the predetermined positions, and
are ready for use, because the lumps 154, 155 and 156 being
integrally connected with the projections through the openings
145, 146 and 147 tightly engages with the openings due to the
shrinkage of synthetic resin in the opening.
Since the U-shaped spring 140 is fixedly held at
one end portion 141, the other end portion 142 thereof may
serve as a spring means effecting ~n one of the components
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" lQ9~522
in the device, for example, a lever 160, as shown in Fig. 42.
Referring to Fig. 42, the lever 160 is rotatablymounted on the pin projection 143 and also displacably along
the pin projection 143. Normally, one corner portion 161 of
the lever 160 is in contact with the U-shaped spring 140 at the
end portion 142, while the other corner portion 162 is
engaged with the engaging projection 144, thus maintaining the
position of the lever 160 between the U-shaped leaf spring
140 and the engaging projection 144. Upon receipt of a suitable
external force, the lever 160 is shifted upwardly for a suitable
distance to disengage from the engaging projection 144, whereby
the lever 160 is rotated about the pin projection 143 in the
clockwise direction for some degrees by the urging force of the
leaf spring 140 so that the lever 160 may be positioned in
one operating position. On the other hand, another suitable
external force may return the lever 160 to its normal enqaged
position.~
It should be noted that the finished pieces, i.e.,
the U-shaped leaf spring 140 described as obtained after the
molding process can be formed in any desirable configuration,
since synthetic resin can be formed into any desirable shape
according to the configuration of the mold. For example,
the end portion 142 of the leaf spring 140 can be formed in a
form of taper, as well as the engaging projection 144, as most
clearly seen in Fig. 41.
It should also be noted that the leaf spring 140
described as employed with a configuration of U-shape, other
shapes of the leaf spring are available, for example, a leaf
spring with a configuration of plain sheet can be employed.
Therefore, according to the present invention, the
synthetic resin projection can be molded as the spring means
by utilizing the elastic force of the synthetic resin.
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~0905Z2
ITEM 6
Referring to Figs. 43 and 44, there is shown acompleted piece of the molded projection P, namely a case
projection 170, being fixedly installed on the base plate B.
Under the base plate B are four lumps 171, 172, 173 and 174
of synthetic resin positioned immediately below the center
of each side of the box-like case pr~ject~on 170.
In order to form such case projection, the base
plate B is previously formed with an opening 175 having four
branches 176, 177, 178 and 179 in the form of the cross, as shown
in Fig. 45, which is substantially equal to the cross formed
by connecting the opposing lump, i.e., the lump 171 with the
lump 173, and the lump 172 with the lump 174. It should be
noted that the width of each branch in the cross is not
- wider than the diameter of each lump. The~ the base
plate B is tightly held between the upper and lower molding
blocks Ml and M2 as best shown in Fig. 46. The upper molding
block Ml has a recess 180 which corresponds with the configuration
of the case projectlon 170 and a groove 181 extending from
said recess towards the one of the neighboring recess ~not
shown). On the other hand, the lower mold~ng block M2 has
four shallow recesses 182, 183, 184 and 185 which correspond
with the lumps 171, 172, 173 and 174. After effecting the
molding process in the same manner as described above, the
ejected piece, i.e., the case projection 170, is fixedly
provided on the base plate ~, because the lumps 171, 172, 173
and 174 being integrally connected with the case projection
170 through the opening 175 tightly engages with the opening
175 due to the shrinkage of the synthetic resin in the openings.
The reason for forming the cross opening in the
base plate is that the lumps 171, 172, 173 and 174 formed
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10905Z2
at the ends of the cross may shift along the branches 176, 177,
178 and 179 of the opening towards the center portion thereof
when shrinking proceeds in the case projection 170, and yet
still the lumps tightly holding the base plate.
If there were no cross in the base plate B, but only
four openings at the ends of the cross, as shown in Fig. 47,
the lumps may not allow the base portion of the case projection
170 to shrink, while the upper rim portion of the case projection
may shrink inwardly so that the case projection itself becomes
deformed in the shape of frustum of a square pyramid, as shown
in Fig. 48.
Therefore, the case projection 170 formed on the
opening 175 in the shape of the cross is especially suitable
for those case projections which requires high accuracy in
their sizes.
It should be noted that the case projection 170
described as formed on the crossing opening 175 can be replaced
by any other type of projection which are formed by large mass
of synthetic resin.
It should also be noted that the opening 175 described
; as formed in the shape of cross is not limited to the cross with
four branches 176, 177, 178 and 179 but the crosses with more
than four branches can be employed, or the branches ln the
shape of 'Y' can be employed, as long as the branches may be
extended in the direction of the radial directions from the
center of the opening, and if possible, it is better to make
the center of the opening coincide with the center of the base
of the molded synthetic resin piece.
ITEM 7
Referring to Figs. 49 and 50, there ls shown a
completed piece of the molded projection P, which has the
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1090522
same configuration as that of the case projection 170 described
in the Item 6. However, the case projection 190 in this Item 7
is molded on different shape of opening formed in the base plate
B. Since the configuration of the case pro~ection 190 and the
recesses to be formed in the upper and lower molding blocks
are exactly the same as those described in the Item 6, the
detail explanation therefore is omitted. Therefore, in
this Item 7, the description is mainly directed to the opening
to be formed in the base plate B.
Referring to Fig. 51, there is shown an opening 191
having four branches 192, 193, 194 and 195 to be formed in the
base plate B. Although this opening 191 also has the form of
cross, each branch of the four branches has not the width in
the same size throughout the branches as in the branches in
the Item 6, but has the width of the branches growing larger
towards the end of the branches.
It should be noted that the width at the end of
each ~ranch is not as large as the width of the lumps to be
formed thereat, even if the width of the branches grow
large towards the end.
Referring to Fig.52, there is shown one of the branch
of the opening in the enlarged scale. The edge of the branch
extends along on the line radially extendlng from the
geometrical center point O, in other words, the edge of the
opening itself directs towards geometrical center point O.
As in the same manner, all the other edges forming the
opening directs towards the geometrical center point o.
Since the molten synthetic resin filled in the
opening 191 tends to shrink towards the geometrical center
point O, an particle of the molten synthetic resin positioned
at Q also tends to shrink towards the geometrical center
point O, in other words shrinks along the edge thereof.
-33-
~Q~052Z
Therefore, the ~olten synthetic resin filled in the opening191 fittingly shrink along the opening without producing
any space between the edge of the synthetic resin and the
edge of the opening, nor producing any intolerable force
on the base plate to such an extent as to deform the base plate.
It should be noted that the projection described
as formed on the crossing opening can be replaced by any
other type of projection which are formed by large mass of
synthetic resin.
It should also be noted that the opening described
as formed in the shape of a cross is not limited to the cross
with four branches but the crosses with more than four
branches are available, as long as the branches extend in
the direction of the radial directions with their edges
coinciding with the line radially extending from the geo-
metrical center point of the opening, and if possible, it
is more preferable to make the center the said geometrical
center point coincide with the center point of the base
of the molded synthetic resin piece.
Therefore, according to the present invention,
it is possible to form the synthetic resin projection of
large sizes, without having such trouble as to deform the
configuration of the projection or cause the base plate to
curve inwardly, due to the shrinkage of the synthetic resin,
because the shrinking force of the synthetic resin is total-
ly absorbed within the projection itself.
ITEM 8
Before going into the detailed description for the
Item 8, it is to be noted that the descriptions up to the
Item 7 have been directed to each of the projections on the
base plate, while the descriptions in the Items from 8 to 14
-34-
10905Z2
are directed to the runners connecting two projections. Althoughthere is no problem in the runners whose shrinkage hardly effects
the base plate or the projections except for merely connecting
two of the neighboring projections, there are such problems
on those runners which connect two projections spaced from each
other by a comparatively large distance, as described hereinbelow.
First, when the runners are comparatively long, the
shrinkage of the runners especially in the longitudinal
direction thereof may effect the base plate to curve inwardly
with respect to the degree of the shrinkage of the runners, as
shown in Fig. 57.
Secondly, when the runners are comparatively long,
the shrinkage thereof cause the connecting two projections to
tilt inwardly towards each other, or otherwise to rotate the
projection undesirably if the runners are extended in L-shape,
as shown in Fig. 75.
~ hirdly, when the runners are comparatively long,
such runners may hinder other projections to be installed
between the two projections being connected by the runners,
as shown in Fig. 79.
In order to solve these problems, such runners des-
cribed in the Items from 8 to 14 are presented.
Now, it should be noted that the runner formed by
a groove which is formed in the molding block between recesses
for allowing molten synthetic resin to flow therethrough may
be cleared away from the framework after being ejected from
the mold, but such a clearing away process results in increase
in the manufacturing cost for manufacturing the framework.
Referring to Figs. 53 and 54, there are shown completed
pieces of two boss projections 200 and 201, being connected to
each other with runners 202 and 203 provided on both sides of
the base plate ~. Each of the two boss projections 200 and 201
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~0905Z2
is a cylindrical projection with a coaxial cylindrical recesson the top portion thereof, and is fixedly installed on the
base plate B by lumps 204 and 205 formed immediately below
the base plate B at positions opposing the boss projections 200
and 201, respectively. The runner 202 connects the bottom
portion of the boss projection 200 with the bottom portion of
the boss projection 201 in straight form, while the runner 203
connects the lump 204 with the lump 205 is exactly the same form
with the former runner 202. It is to be noted that at least one
of the boss projections is connected to any one of the neigh-
boring projection. In order to form such runners 202 and 203
between the two boss projections 200, and 201 the base plate
B is preliminarily provided with two openings 206,-and 207, as
shown in Fig. 55. Then the base plate B is sandwiched between
upper and lower molding blocks Ml and M2, as shown in Fig. 56.
The upper molding block Ml is provided with a groove 208 which
connects two recesses 209 and 210 for molding boss projections
200 and 201, while the lower molding block ~2 is formed with a
groove 211 connecting two shallow recesses 212 and 213 for the
lumps 204 and 205, respectively.
After effecting the molding process in the same manner
as described above, the ejected runners 202 and 203 connects
the boss projections 209 and 210 in the manner as described
above.
Since the runners provided on both sides of the
base plate B have exactly the same form, the degree of the
shrinkage taking place in the runners 202 and 203 is also
exactly the same amount. Therefore, the shrinking force
in the runner 202 has exactly the same amount of shrinking
force in the runner 203, thus resulting in precise positioning
of the projection.
-36-
1090522
Therefore, according to the present invention, the
shrinking force of the runner 204 connecting the two boss
projections do not effect the base plate, because said shrinking
force of the runner 202 is relatively eliminated by the other
runner 203 provided on the opposite side of the former runner
202.
ITEM 9
Referring to Figs. 58 and 59, there is shown completed
pieces of the two boss projections 220 and 221 being connected
by a runner 222, provided between the two boss projections
220 and 221. Each of the two boss projections 220 and 221 are
fixedly installed on the base plate B by lumps 223 and 224
formed immediately below the base plate B at positions opposing
the boss projections 220 and 221, respectively. The two
opposite end portions 225 and 226 of the runner 222 are laid
on an imaginary straight bridge K, connecting the boss projections
220 and 221, while the intermediate portion 227 of the runner
222 is curved aside substantially in the form of an arc from
the lmaginary straight bridge K on the base plate B.
In order to form such runner 222 disposed between
the boss projections 220 and 221, the base plate B is pre-
liminarily formed with two openings 228 and 229, as shown
in Fig. 60. Then, the base plate B is sandwiched between
the upper and lower molding blocks Ml and M2. The upper
molding block Ml is formed with groove 230 connecting two
recesses 231 and 232 for the boss projections 220 and 221,
while the lower molding block M2 only has shallow recesses
233 and 234 for forming the lumps 223 and 224 thereat to hold
the boss projection 220 and 221, respectively. The groove
230 in the upper molding block Ml corresponds with the shape
of the runner 222.
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1~905ZZ
After effecting the molding process in the same manner
as described above, the ejected runner 222 may shrink for some
degrees, in the process of cooling. However, since the runner
222 is not tensed between the two boss projections 220 and 221,
the shrinking force of the runner do not affect the boss pro-
jections nor the base plate B. In other words, the shrinklng
force of the runner 222 is totally absorbed in the curved portion
227 of the runner 222, causing the curvature of the curved
portion 227 to be stretched for some degrees with respect to the
degrees of the shrinkage, as shown in dotted line in Fig. 58.
It should be noted that the intermediate portion 227
of the runner 222 described as formed in the shape of an arc
can be formed in any other form than the straight line,such as
in the form of zigzag, as shown in Fig. 62, resulting in the
same effect as described above.
It should be noted that the runner 242 described as
formed on the upper surface of the base plate B can be formed
on the lower surface of the base plate B.
Therefore, according to the present invention, the
runner 222, connecting the two boss projections does not effect
the base plate nor the boss projections by its shrinking force,
because the wave or zigzag form of the runner absorbs lts own
shrinking force therein.
ITEM 10
Referring to Figs. 63 and 64, there is shown completed
pieces of the two boss projections 240 and 241, being connected
to each other with a runner 242 extended between the bottom of
the boss projections 240 and 241, in straight form. Each of
the two boss projections 240 and 241 are fixedly installed on
the base plate B by lumps 243 and 244 formed immediately below
the base plate B at position opposing the boss projections
240 and 241, respectively. The runner 242 has at least one
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10905ZZ
narrowed portion 245 formed at intermediate portion thereof.
In order to form such runner 242 between the boss pro-
jections 240 and 241, the base plate B iS preliminarily formed
with two openings 246 and 247, as shown in Fig. 65. Then the
base plate B iS sandwiched between upper and lower molding
blocks Ml and M2. ~he upper molding block Ml is provided with
a groove 248 connecting two recesses 249 and 250 which are
prepared for molding the boss projections 240 and 241. The
groove 248 has a narrowed portion 251 at corresponding narrowed
portion 245 of the runner 242. On the other hand, the lower
molding block M2 only has shallow recesses 252 and 253 for
forming the lumps 243 and 244 thereat to hold the boss projections
240 and 241, respectively. It should be noted that the recess 250
is connected to another groove 254 for allowing the molten synthe-
tic resin therefrom into the recess 250 and further to the
recess 249.
After effecting the molding process in the same manner
as described above, the ejected runner 242 may shrink for some
degrees, mostly in the longitudinal direction thereof, in
the process of cooling.
Since the runner 242 has the narrowed portion 245
therein, such shrin~ing force in the runner 242 can be mostly
absorbed in the narrowed portion 245, because the shrinking force
is most likely to affect the narrowed portion 245 in such
a manner as to stretch the narrowed portion rather than to
tilt the two boss projections 240 and 241 towards each other
or bend the base plate B.
It should be noted that the narrowed portion 251 in
the groove 248 is preferably to be formed at a position close
to the recess 249, because in the process of molding, less
amount of molten synthetic resin passes through the narrowed
portion 251 in the groove 248, when compared with such a
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groove (not shown) which has the narrowed portion close to the
recess 250, resulting in much amount of molten synthetic resin
to pass through the narrowed portion.
It should also be noted that the runner 242 described
as formed on the upper surface of the base plate B can be
formed on the lower surface of the base plate B, and yet
producing the same effect. In this case, the runner 242 is formed
between the lumps 243 and 244.
Therefore, according to the present invention, the
most of the shrinking force of the runner 242 causes the
narrowed portion 245 to be stretched, thus scarcely affecting
the base plate nor the boss projections so as to deform their
configurations.
ITEM 11
Referring to Figs. 67 and 68, there is shown completed
pieces of the two boss projections 260 and 261, being connected
by a runner 262, stretched between the boss projections 260 and
261. Each of the two boss projections 260 and 261 are fixedly
installed on the base plate B by lumps 263 and 264 formed immed-
lately below the base plate B at positions opposing the bossprojections 260 and 261, respectively. The runner 262 is
also fixedly supported on the base plate B by lumps 265 and 266
formed immediately below the base plate B at positions adjacent
to the lumps 263 and 264, and on the line connecting the lumps
263 and 264.
In order to form such runner 262 connecting the
boss projections 260 and 261, the base plate B is preliminary
formed with openings 267, 268, 269 and 270. The larger
openings 267 and 268 are prepared for integrally connecting
the boss projections 260 and 261 with the lumps 263 and 264,
respectively, while the smaller openings 269 and 270 are
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prepared for integrally connecting the runner 262 with the lumps265 and 266. Then, the base plate B is sandwiched between the
upper and lower molding blocks Ml and M2 as shown in Fig. 69.
The upper molding block Ml has two recesses 271 and 272 for
molding the boss projections 260 and 261, and also has a groo~e
273 extending between the recesses 271 and 272. On the other
hand, the lower molding block M2 has four shallow recesses
274, 275, 276 and 277.
The shallow recesses 274 and 275 are for molding the
lumps 263 and 264, respectively, while the shallow recesses 276
and 277 are for molding the lumps 265 and 266, respectively.
It should be noted that the recess 272 is further
connected with another groove 278 for receiving the molten
synthetic resin therefrom into the recess 272 and further to
the recess 271.
After effecting the molding process in the same manner
as described above, the ejected runner 262 may shrink to some
degrees, mostly in the longitudinal direction thereof, in the
process of cooling. Since the runner 262 is fixedly held on
the base plate B by the lumps 265 and 266 integrally formed
with the runner 262, the shrinking of the runner 262 mostly
takes place in the runner portion defined by the two lumps
265 and 266. Therefore, the effect of the shrinking hardly
affects the boss projections 260 and 261, thus the boss projections
260 and 261 can be maintained in the predetermined position even
the runner portion between the two lumps 265 and 266 shrinks for
some degrees.
It should be noted that the runner 262 described as
formed integrally with the two lumps 265 and 266 can be formed
with only one lump positioned approximately at the center portion
of the runner 262, or more than two lumps with respect to the
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length of the runner 262 to be formed between the boss projections.
It should also be noted that the runner 242 describedas formed on the upper surface of the base plate B can be formed
on the lower surface of the base plate B.
Therefore, according to the present invention, the
shrinking force of the runner 262 is mostly intercepted by the
lumps 265 and 266, thus preventing said shrinking force from
effecting on the boss projections.
ITEM 12
Referring to Figs. 70 and 71, there is shown completed
pieces of the two boss projections 280 and 281, being connected
by a L-shaped runner 282. It is necessary to form such L-shaped
runner between the boss projections 280 and 281 when the space
between the boss projection must be left open for installing one
of the components 283 thereat. The boss projection 280 has
exactly the same configuration as the boss projection described
in Item 8. On the other hand, the boss projection 281 has a
plate-like projection 284 formed on the top portion thereof,
lnstead of the cylindrical recess. Each of the boss projections
280 and 281 are fixedly installed on the base plate B by lumps
285 and 286 formed immediately below the base plate B at
positions opposing the boss projections 280 and 281, respectively.
The L-shaped runner 282 has its corner portion 287 being fixedly
installed on the base plate B by a lump 288 formed immediately
below the base plate B at position opposing the corner portion
287.
In order to form such boss projections on the base
plate B with the L-shaped runner 282 connecting these two boss
projections 280 and 281, the base plate B is preliminarily formed
with three openings 289, 290 and 291. The larger openings 289
and 290 are prepared for integrally connecting the boss
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projections 280 and 281 with the lumps 285 and 286, respectively,
while the smaller opening 291 is prepared for integrally connecting
the corner portion 287 of the runner 282 with the lump 288. Then,
the base plate B is sandwiched between the upper and lower molding
blocks Ml and M2. The upper molding block Ml has two recesses
292 and 293, which correspond with the configuration ~f the boss
projections 280 and 281, respectively, and also a L-shaped groove
294 for connecting the two recesses 292 and 293. On the other
hand, the lower molding block M2 has three shallow recesses
10 295, 296 and 297 for molding the lumps 285, 286 and 288,
respectively.
It should be noted that the upper molding block Ml
is further formed with a groove 298 extending from the recess
292 towards one of the neighboring recess (not shown) for
receiving the moltensynthetic resin therefrom into the recess
292 and further to the recess 293.
After effecting the molding process in the same manner
as described above, the ejected runner 282 may shrink for some
degrees, in the process of cooling.
Referring to Fig. 75, if the runner 282 were not
provided with the lump 288 which fixedly support the corner
portion 287 thereof on the base plate B, the shrinking force
in the runner 282 not only effects the L-shaped runner 282'
to stretch, but also effect the boss projection 281 to be
twisted in a clockwise direction, as shown in the dotted line
in Fig. 75. However, according to the L-shaped runner 282
of the present invention, the L-shaped runner 282 is fixedly
provided on the base plate at the corner portion 287, the
shrinking of the runner 282 proceeds within the straight
sections of the L-shaped runner 282. In other words, the effect
of the shrinking force in one of the straight sections of the
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L-shaped runner is absorbed within the same straight section,
while the effect of the shrinking force in the other straight
section is absorbed within the same straight section. Therefore,
the shrinking force of the runner 282 effects each of the boss
projections only in their radial direction, thus producing no
twisting force on the boss projection 281, resulting in precise
positioning of the boss projection 281.
It should be noted that the runner 282 described as
formed in the shape of L, can be formed in any zigzag form,
in relation to the configuration of the component to be
placed between the boss projections 280 and 281. In this case,
the lump may be formed at the nearest corner portion to the
boss projection.
It should also be noted that the runner 282 described
as formed on the upper surface of the base plate B,can be
formed on the lower surface of the base plate B.
Since the L-shaped runner 282 is fixedly installed
on the base plate at corner portion 287, the shrinking force
of the L-shaped runner is intercepted at corner portion 287
thereof, thus preventing relatively effecting the shrinking
force. Therefore, the boss projections do not receive any
twisting force by the L-shaped runner 282.
ITEM 13
Referring to Figs. 76 and 77, there is shown completed
piece of the two boss projections 300 and 301, being connected
by a runner 302. Each of the two boss projections 300 and 301
is fixedly installed on the base plate B by lumps 303 and 304
formed immediately below the base plate ~ at positions opposing
the boss projections 300 and 301, respectively. The runner 302,
extended between the two boss projections 300 and 301 has two
sections. The section 305, formed immediately below the base
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plate B extends from the lump 304 towards the other lump 303,but only up to a little more than half the distance between
the two lumps 303 and 304, in a similar manner the section
306, formed on the upper surface of the base plate B extends
~rom the base portion of the boss projection 300 towards the
base portion of the other boss projection 301, but only up to
a little more than half the distance between the two boss
projections 300 and 301, so that in the middle portion of
these two boss projections 300 and 301, the end portion of the
section 305 overlaps with the end portion of the section 306, via
base plate B existing between the two section 305 and 306. In
said middle portion, these two section 305 and 306 are integrally
connected to each other, as best shown in Fig. 77.
In order to form the two boss projections 300 and 301
being connected with such runner 302, the base plate B is
preliminarily formed with three openings 307, 308 and 309,
as shown in Fig.79. The larger openings 307 and 308 are
prepared for integrally connecting the boss projections 300
and 301 with the lumps 303 and 304, respectively, while the
smaller opening 309 is prepared for integrally connecting the
runner in the section 306 with the same in the section 305.
Then, the base plate B is sandwiched between the upper and
lower molding blocks Ml and M2. The upper molding block Ml
has two recesses 310 and 311 for molding the boss projections
300 and 301, and also a groove 312 extending from the recess
310 towards the other recess 311, but only up to a little more
than half the distance between the two recesses 310 and 311. On
the other hand, the lower molding block ~2 has two shallow
recesses 313 and 314 ~or molding the lumps 303 and 304, and
also a groove 315 extending from the shallow recess 314 towards
the other shallow recess 313, but only up to a little more than
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half the distance between the two recesses 313 and 314.
It should be noted that the shallow recess 314 isfurther connected with another groove 316 for receiving the
molten synthetic resin therethrough into the recesses 311 and 310.
After effecting the molding process in the same manner
as described above, the ejected runner 302 may shrink to some
degrees, mostly in the longitudinal direction thereof, in the
process of cooling. Since the runner 302 connecting the two
boss projections 300 and 301 is divided into two sections 305
10 and 306, the amount of shrinkage produced in each section is not
as large as the amount of shrinkage in the runner which directly
connects two boss projections.
Furthermore, since the runner extends only up to
approximately half the distance between the boss projections,
it is possible to provide some component or components directly
on the base plate in the rest of the opened space between the
two boss projections 300 and 301, as shown in Fig. 80.
It should be noted that the runner 302 described as
formed in two separate sections 305 and 306, can be formed by
20 more than two sections alternately above and below the base
plate B, in relation to the distance between the two boss
projections, or in relation to the positioning of the component
to be installed on the base plate.
Since the runner 302 is divided into two sections,
the shrinking force of the runner 302 is reduced to half when
compared with a runner shown in Fig. 57, resulting in less
shrinking force effecting on the boss projections. Furthermore,
since the runner 302 only covers half the way between the
boss projections, it is possible to install some components
30 on the other half.
ITEM 14
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lO90S2Z
Referring to Figs. 81 and 82, there is shown completed
pieces of two boss projections 320 and 321, being connected by a'
runner 322. Each of the two boss projections 320 and 321 are
fixedly installed on the base plate B by lumps 323 and 325
formed immediately below the boss projections 320 and 321,
respectively. The runner 322, extended between the two boss
projections 320 and 321 is completely buried in the base plate
B, as best shown in Fig. 82.
In order to form the two boss projections 320 and 321
being connected with such runner 322, the base plate B is
preliminarily formed with three openings 325, 326 and 327, as
best shown in Fig. 83.
The openings 325 and 326 are prepared for integrally
connecting the boss projections 320 and 321 with the lumps
323 and 324, respectively, while the elongated opening 327 formed
in the space between the openings 32'5 and 326 is,,.prepared
for forming the runner 322 therein. Then the base plate B
is sandwiched between the upper and lower molding blocks Ml
and M2. The upper molding block Ml has two recesses 328 and
329, while the lower molding block M2 has two shallow recesses
330 and 331.
It should be noted that the size of the opening of
the recess 328 formed in the upper molding block Ml and the
same of the shallow recess 330 formed in the-lower molding
block have such a large opening to cover, when sandwiching
the base plate B, not only the opening 325 formed in the
base plate B, but also a part of the elongated opening 327.
In a similar manner, the opening of the other recess 329 formed
in the upper molding block Ml and the same of the shallow
recess 331 formed in the lower moldinq block M2 also covers
a part of the elongated opening 327, together with the opening
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326 formed in the base plate B so that the cavity for the boss
projections 320 and 321 can be connected with the elongated
opening when the upper and lower molding blocks Ml and M2
sandwich the base plate B.
It should also be noted that the shallow recess 331
must be connected with a groove 332 for receiving themolten
synthetic resin therethrough into the cavity.
After proceeding the molding process in the same
manner as described above, the ejected runner 322 may shrink
to some degrees, mostly in the longitudinal direction thereof,
in the process of cooling. Since the runner 322, connecting the
two boss projections 320 and 321 is completely buried in the
elongated opening 327, the shrinking force of the runner can
be absorbed in the elongated opening 327, thus exerting no
serious force on the boss projections 320 and 321 to deform
the conflgurations therof. Furthermore, since the runner 322
is not projecting from the surfaces of the base plate B, it is
possible to provide some component or components in any space
between the two boss projections 320 and 321.
It should be noted that the runner 322 described as
molded in the elongated opening 327 can be molded in a elongated
groove formed at least on one side of the base plate B.
It should also be noted that the elongated opening
described as formed in the space between the-two openings 325
and 326 can be connected with the openings 325 and 326 at their
opposite ends, as shown in Fig.85, and also can be provided with
numbers of branches to form more runners for connecting more
than two projections.
Since the runner 322 connecting the two boss projections
is mounted in the openings 327, the effect of the shrinking force
of the runner 322 is limited in the opening 327, thus preventing
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said shrinking force from affecting the boss projections.Furthermore, since the runner 322 does not project from the
surface of the base plate B, it is possible to lay some components
across the runner 322 without difficulty.
It should be noted that the base plate described
as composed of metallic plate can be replaced by any other
type of plate as long as the plate does not deform in the
configuration thereof at the melting temperature of the synthetic
resin.
It should also be noted that the various runners
described as employed for connecting boss projections is not
necessarily used for connecting the boss projections, but may
be used for connecting any other types of the synthetic resin
projections.
It should also be noted that the boss projections or
any other projections described as fixedly formed on the upper
surface of the base plate, can be formed on the lower surface
of the base plate, when it is necessary, by a suitable recess
formed in the lower molding block.
As described in detail hereinabove, the synthet~c
resin projections to be installed on the base plate to construct
the framework, can all be formed at once by the process of molding,
and yet the positioning of each of the projections can be
effected with accuracy.
Although the present invention has been fully described
by way of examples with reference to the attached drawings,
~ it is to be noted that various changes and modifications are
; apparent to those skilled in the art. Therefore, unless
otherwise, such changes and modifications depart from the
scope of the present invention, they should be construed as
included therein.
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