Description

CASE FOR ELECTRONIC APPARATUS AND METHOD OF MANUFACTURING CASE FOR ELECTRONIC APPARATUS

Technical Field

[1] The present invention relates to a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus, and more particularly, to a method of manufacturing a case for an electronic apparatus easily and efficiently. Background Art

[2] Generally, a case for an electronic apparatus is used to form its appearance and at the same time protect inner parts from external impact and prevent foreign substances such as dust from entering the inside of the electronic apparatus.

[3] FIG. 1 is a sectional view illustrating a structure of a conventional case for an electronic apparatus.

[4] Referring to FIG. 1, the conventional case includes a case body 10, a lower coating layer 20, and an upper coating layer 30, wherein the lower coating layer 20 and the upper coating layer 30 are sequentially formed on a surface of the case body 10.

[5] The case body 10 is generally formed by injection molding, and the lower coating layer 20 and the upper coating layer 30 are formed on the case body 10 in a spray type of coating liquid.

[6] The lower coating layer 20 is formed on the surface of the case body 10 and provides a background color of the case. The upper coating layer 30 is formed of a transparent material to serve as a protection layer for protecting the surface of the lower coating layer 20.

[7] However, such a conventional spray type for forming the lower coating layer 20 and the upper coating layer 30, which constitute the case, has a problem in that a working process is inconvenient and complicated. For this reason, problems occur in that the manufacturing cost increases and workability and productivity are deteriorated.

[8] Furthermore, the conventional method of forming the coating layers 20 and 30 in a spray type has problems in that the thickness of each of the coating layers 20 and 30 is not uniform and a lot of coating liquids are unnecessarily consumed.

[9] Moreover, the conventional case has a problem in that if the upper coating layer 30 and the lower coating layer 20 are peeled away, the case body 10 having a background color different from that of the lower coating layer 20 is directly exposed to the outside, thereby causing messy appearance. Disclosure of Invention Technical Problem

[10] The present invention is to provide a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus, in which a working process can be simplified, the manufacturing cost can be reduced, and productivity can be improved.

[11] The present invention is to provide a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus, in which a working process can be simplified using an ultra-speed double injection process and the manufacturing cost can be reduced.

[12] The present invention is to provide a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus, in which clean appearance of the product can be maintained.

[13] The present invention is to provide a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus, in which flow of foreign substances into the product can be reduced and reliability can be prevented from being deteriorated due to flow of foreign substances. Technical Solution

[14] According to one exemplary aspect of the present invention, a method of manufacturing a case for an electronic apparatus comprises the steps of providing a case body; arranging the case body inside a mold; injecting a melted resin between a surface of the case body and the mold; and forming a thin film injection layer on the surface of the case body through double injection molding by solidifying the melted resin.

[15] If the melted resin is injected at high speed, the thin film injection layer can be formed thinly. At this time, the resin can be injected at speed of 1000 ~ 1500mm/s, and the thin film injection layer can be formed by double injection molding at thickness of 0.2 ~ 0.6mm.

[16] Various kinds of resins can be used in accordance with required conditions and product options. For example, a transparent resin such as acrylic resin and polycarbonate resin can be used as the resin. Also, materials for improving feeling, i.e., rubber, urethane and silicon, which can form a soft feeling (SF) coating layer having relatively low hardness, can be used as the resin.

[17] In the steps of injecting and solidifying the resin, a regulator for regulating a temperature of the mold flows along a temperature regulating line formed inside the mold. The regulator flows along a temperature regulating line inside the mold, and the temperature of the mold can be maintained at a given temperature or greater during injection of the resin, while the temperature of the mold can be lowered during solidification of the resin.

[18] Also, the regulator can be provided at the same temperature during injection of the resin and solidification of the resin. The temperature condition of the regulator can be

changed freely depending on types and features of the resin. As the case may be, the regulator can be provided at different temperatures when the resin is injected and solidified.

[19] To uniformly regulate the temperature of the mold, the temperature regulating line has different inlets and outlets, and includes a plurality of regulating lines arranged on different regions. The number of the regulating lines and their arrangement can be changed depending on the required conditions.

[20] After the thin film injection layer is formed, a spray coating layer can be formed on the surface of the thin film injection layer in a spray type. Also, a transfer inmold or a film insert can be provided on the surface of the case body in the step of forming the thin film injection layer.

[21] Meanwhile, while the thin film injection layer is formed by ultra-speed double injection molding, a protection window corresponding to a display part of the electronic apparatus can be formed in a single body with the thin film injection layer. To this end, the case body can be provided in a state that it includes a window hole corresponding to the display part, and the mold can be provided in a state that it includes a window shielding part corresponding to the window hole. Accordingly, in the step of forming the thin film injection layer through double injection molding, a protection window corresponding to the window hole can be formed.

[22] For reference, in the present invention, the electronic apparatus can include all electronic apparatuses, which include or do not include a display window. The display window means a window arranged at the front of the display part to output various kinds of information as video information. For example, the electronic apparatus can include portable electronic apparatuses such as personal digital assistant (PDA), smart phone, handheld PC, cellular phone and MPS player. In addition, the electronic apparatus can include facsimile, printer, and telephone.

[23] According to en exemplary embodiment of the present invention, a method of manufacturing a case for an electronic apparatus, the case including a display part, comprises the steps of forming a case body having a window hole corresponding to the display part through injection molding, the case body being formed of an opaque material; arranging the case body inside a mold; injecting a melted light-transmitting resin between a surface of the case body and the mold; and forming a light-transmitting thin film injection layer on the surface of the case body through double injection molding to form a protection window corresponding to the window hole by solidifying the injected light-transmitting resin.

[24] Since the protection window corresponding to the display part of the electronic apparatus is formed in a single body with the light-transmitting thin film injection layer while the light- transmitting thin film injection layer is formed ultra- speed double

injection molding, the manufacturing process can be simplified, the manufacturing cost can be reduce, and productivity can be improved.

[25] The light-transmitting thin film injection layer can be formed to have various features depending on the required conditions and product options. For example, the light- transmitting thin film injection layer has high polish, and can be formed transparently. The light-transmitting thin film injection layer can be formed of an opaque material.

[26] Preferably, the protection window region of the light-transmitting thin film injection layer is formed to have a thickness relatively thicker than that of other regions, thereby maintaining given shape strength. The protection window region can be protruded to the outside of the light-transmitting thin film injection layer as the case may be.

[27] According to an exemplary embodiment of the present invention, a method of manufacturing a case for an electronic apparatus, the case including a camera module, comprises the steps of forming a case body having a camera hole corresponding to the camera module through injection molding, the case body being formed of an opaque material; arranging the case body inside a mold; injecting a melted light-transmitting resin between a surface of the case body and the mold; and forming a light-transmitting thin film injection layer on the surface of the case body through double injection molding to form a camera lens portion corresponding to the camera hole by solidifying the injected light-transmitting resin.

[28] A flash hole corresponding to a flash module can be formed in the case body while the light-transmitting thin film injection layer is formed double injection molding, and a flash lens portion corresponding to the flash hole can be formed in the light- transmitting thin film injection layer while the light- transmitting thin film injection layer is formed by double injection molding.

[29] The light-transmitting thin film injection layer can be formed to have various features depending on the required conditions and product options. For example, the light- transmitting thin film injection layer has high polish, and can be formed transparently. The light-transmitting thin film injection layer can be formed of an opaque material.

[30] Preferably, the camera lens portion region and(or) the flash lens portion region of the light-transmitting thin film injection layer is formed to have a thickness relatively thicker than that of other regions, thereby maintaining given shape strength. The camera lens portion region and the flash lens portion region can be protruded to the outside of the light-transmitting thin film injection layer as the case may be.

[31] When the light-transmitting thin film injection layer including the flash lens portion is formed, an uneven portion can be formed inside the flash lens portion. The uneven portion allows light irradiated from the flash module to be scattered and also allows more natural illumination. The shape and structure of the uneven portion can be changed variously depending on the required condition and design options.

[32] A reflection coating part for providing a mirror surface can be formed inside or outside the light-transmitting thin film injection layer. The reflection coating part may be provided in a flat shape or a convex shape.

[33] For example, a reflection hole can be formed in the case body when the case body is formed by injection molding. The reflection coating part can be formed inside the light-transmitting thin film injection layer exposed to the reflection hole. The reflection coating part can be formed in such a manner that a metal thin film having reflection effect of light is formed through aluminum deposition.

[34] Furthermore, the convex portion can be formed in the light-transmitting thin film injection layer in the step of forming the light-transmitting thin film injection layer through double injection molding. The reflection coating part can be formed inside or outside the convex portion. At this time, the shape and structure of the convex portion can be changed variously depending on the required condition and design options.

Advantageous Effects

[35] As described above, according to the present invention, the working process of the case can be simplified, the manufacturing cost can be reduced, and productivity can be improved. [36] In particular, according to the present invention, since the thin film injection layer of high quality can be formed by ultra-speed double injection molding, it is possible to simplify the manufacturing process of the case, reduce the manufacturing cost, and improve productivity. [37] Furthermore, according to the present invention, it is possible to cleanly and stably appearance of the product and to provide satisfaction to consumers. [38] Furthermore, according to the present invention, since the case can be manufactured by double injection molding, it is possible to remarkably reduce a defect rate and to prevent the resin from being unnecessarily consumed. [39] Furthermore, according to the present invention, since the thin film injection layer can be formed simultaneously with the protection window for protecting the display part, it is possible to simplify the manufacturing process. [40] Finally, according to the present invention, since the protection window or the camera protection window can be formed in a single body with the light-transmitting thin film injection layer, it is possible to prevent foreign substances from flowing into the product, thereby preventing reliability from being deteriorated.

Brief Description of the Drawings [41] FIG. 1 is a sectional view illustrating a structure of a conventional case for an electronic apparatus; [42] FIG. 2 is a block diagram illustrating a method of manufacturing a case for an

electronic apparatus according to one embodiment of the present invention; [43] FIG. 3 and FIG. 4 are a perspective view and a plane view illustrating a case for an electronic apparatus and a molding structure used to manufacture the case according to one embodiment of the present invention; [44] FIG. 5 is a sectional view illustrating a sectional structure of a case for an electronic apparatus of FIG. 3 and FIG. 4; [45] FIG. 6 and FIG. 7 are sectional views illustrating a structure of a case for an electronic apparatus according to another embodiment of the present invention; [46] FIG. 8 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention; [47] FIG. 9 and FIG. 10 are perspective views illustrating a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to one embodiment of the present invention; [48] FIG. 11 is a sectional view taken along line I-I of FIG. 9;

[49] FIG. 12 is a sectional view taken along line II- II of FIG. 9;

[50] FIG. 13 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention; [51] FIG. 14 and FIG. 15 are perspective views illustrating a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to one embodiment of the present invention; [52] FIG. 16 is a sectional view taken along line III-III of FIG. 14;

[53] FIG. 17 is a sectional view taken along line IV-IV of FIG. 14;

[54] FIG. 18 is a sectional view illustrating a structure of a case for an electronic apparatus according to another embodiment of the present invention; [55] FIG. 19 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention; [56] FIG. 20 and FIG. 21 are perspective views illustrating a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to one embodiment of the present invention; and [57] FIG. 22 is a sectional view taken along line V-V of FIG. 20.

Best Mode for Carrying Out the Invention [58] Hereinafter, the preferred embodiments of the present invention will be described with reference to the accompanying drawings. However, it is to be understood that the present invention is limited to the embodiments. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Under this rule, description of one drawing will be made with reference to that of another drawing, and the description apparent to those skilled in the art or repeated de-

scription will be omitted.

[59] FIG. 2 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention, FIG. 3 and FIG. 4 are a perspective view and a plane view illustrating a case for an electronic apparatus and a molding structure used to manufacture the case according to one embodiment of the present invention, and FIG. 5 is a sectional view illustrating a sectional structure of a case for an electronic apparatus of FIG. 3 and FIG. 4.

[60] As illustrated in the above drawings, the case for an electronic apparatus according to the present invention is manufactured by ultra-speed double injection molding.

[61] A general injection molding (injection speed of resin is within 500mm/s) has a problem in that it is difficult to mold a thin film. Namely, if a melted resin flows within a mold, its fluidity is rapidly lost. In this case, if injection speed of the resin is slow, melting viscosity is rapidly deteriorated for a short time, and problems, such as short shot failing to fully fill a molding cavity, flow mark, weld line, and poor surface polish, occur. Accordingly, in order to form a thin film through injection molding, a high injection speed and uniform temperature of a mold are required.

[62] Furthermore, a thickness of a product manufactured by injection molding is very important in view of production efficiency. In other words, if the thickness of the product manufactured by injection molding becomes thin, cooling time can be shortened. This can shorten cycle time and improve productivity. Also, reduction in the thickness of the product manufactured by injection molding could lead to lightweight and reduction of the manufacturing cost.

[63] Accordingly, the present invention is intended to form a thin film of high quality through ultra-speed injection molding, as described in detail below.

[64] As illustrated in the drawings, the case for an electronic apparatus according to the present invention can be manufactured by the steps of providing a case body 110, arranging the case body 110 inside a mold 200, injecting a melted resin between the surface of the case body 110 and the mold 200 at high speed, and forming a thin film injection layer 120 on the surface of the case body 110 through double injection molding by solidifying the melted resin.

[65] First of all, the case body 110 is provided, and can be formed by a general injection molding of a plastic resin. The case body 110 can be formed of a metal material as the case may be, or can be manufactured by other processing methods.

[66] Next, a general insert process method can be used to arrange the case body 110 inside the mold 200. If the insert process method is used, the case body can be manufactured separately and then can be arranged inside the mold.

[67] Preferably, in order to simplify the whole manufacturing process, a double injection molding process can be used in such a manner that the case body is formed inside the

mold through primary injection molding and then an upper mold required for secondary injection molding is only exchanged with another one without detaching the formed case body from the mold, so as to arrange the case body inside the mold.

[68] Subsequently, the melted resin is injected into a cavity between the surface of the case body 110 and the mold 200 at high speed. In this case, high-speed injection of the resin means that the resin is injected at injection speed of 1000 mm/s or greater. Preferably, the resin is injected at injection speed of 1000 ~ 1500 mm/s. More preferably, the resin is injected at injection speed of 1500 ~ 2000 mm/s.

[69] Various kinds of resins can be used in accordance with required conditions and product options. For example, transparent resin such as acrylic resin and polycarbonate resin can be used as the resin. Also, materials for improving feeling, i.e., rubber, urethane and silicon, which can form a soft feeling (SF) coating layer, can be used as the resin. Moreover, a resin of an opaque material can be used.

[70] Next, a thin film injection layer 120 is formed on the surface of the case body 110 by double injection by solidifying the injected resin, whereby manufacture of the case can be completed. In other words, in this step, as the resin filled in the cavity between the surface of the case body 110 and the mold 200 is solidified, the thin film injection layer 120 can be formed on the surface of the case body 110 in a single body with the case body 110.

[71] The thin film injection layer 120 formed by ultra- speed dual molding as above can have a thickness of 0.2 ~ 0.6 mm, preferably 0.2 ~ 0.3mm.

[72] Meanwhile, while the step of forming the thin film injection layer 120 through double injection, i.e., the resin is injected and solidified, a regulator for regulating a temperature of the mold 200 can flow along a temperature regulating line 210 formed inside the mold 200.

[73] In other words, even though the resin is melted at high temperature and then injected into the mold 200 at high speed, if the temperature of the mold 200 decreases at a given temperature or less, the resin flowing along the narrow cavity between the surface of the case body 110 and the mold 200 may lose its fluidity rapidly. Accordingly, the mold 200 should be maintained at a given temperature to prevent the fluidity of the resin from being deteriorated when the resin is injected.

[74] Also, if the temperature of the mold 200 is too high, cooling time of the resin becomes longer and cycle time becomes longer. Accordingly, the temperature of the mold 200 should be lowered to shorten the cooling time of the resin when the resin is solidified.

[75] As illustrated in FIG. 3 to FIG. 5, the temperature regulating line 210 can be provided inside the mold, and the regulator for regulating the temperature of the mold 200 along the temperature regulating line 210 can flow. As described above, the

regulator flows along the temperature regulating line 210 inside the mold 200, and the temperature of the mold 200 can be maintained at a given temperature or greater during injection of the resin, while the temperature of the mold 200 can be lowered during solidification of the resin.

[76] Also, the regulator can be provided at the same temperature during injection of the resin and solidification of the resin. For example, if the polycarbonate resin is used, the regulator can be provided at a temperature of 12O ⁰ C, approximately. The temperature condition of the regulator can be changed freely depending on types and features of the resin. As the case may be, the regulator can be provided at different temperatures when the resin is injected and solidified.

[77] A liquid regulator, such as cooling water, hot fluid, hot water, and cooling fluid, can be used as the regulator. Otherwise, a vapor regulator such as steam can be used as the regulator. It is to be understood that the features and types of the regulator do not restrict or limit the present invention.

[78] Preferably, the temperature regulating line 210 is provided with different inlets and outlets, and includes a plurality of regulating lines arranged on different regions. Also, each regulating line is preferably formed in a round shape along the contour of a molding part inside the mold 200. In this case, the regulator can flow independently through the plurality of regulating lines, which are specially designed and arranged, and the temperature of the mold 200 can be regulated uniformly without local temperature change. Although the temperature regulating line 210 includes two regulating lines, which are arranged on different regions, in the embodiment of the present invention, three regulating lines can be provided as the case may be, and their arrangement can be changed depending on the required condition.

[79] FIG. 6 and FIG. 7 are sectional views illustrating a structure of a case for an electronic apparatus according to another embodiment of the present invention.

[80] Referring to FIG. 6, after the thin film injection layer 120 is formed, a spray coating layer 130 can be formed on the surface of the thin film injection layer 120 in a spray type. The spray coating layer 130 can be formed in a spray type using a general spray gun, and is formed on the surface of the thin film injection layer 120 to serve as a protection layer for protecting the thin film injection layer 120 and at the same time serve to maintain good appearance. This spray coating layer 130 can be formed of a transparent material with polish. Alternatively, the spray coating layer 130 can be formed of an opaque material having an unpolished feature.

[81] Although the thin film injection layer 120 is directly formed on the surface of the case body 110 in the aforementioned embodiment of the present invention, a transfer inmold 140 or a film insert can be provided on the surface of the case body 110 before the thin injection layer 120 is formed or when the thin injection layer 120 is formed as

illustrated in FIG. 7.

[82] The transfer inmold 140 or the film insert is interposed between the case body 110 and the thin injection layer 120 to substantially determine a background color and pattern of the case. The transfer inmold 140 or the film insert can be coated with various patterns and colors in accordance with the required condition. The transfer inmold 140 or the film insert can be patterned with a three-dimensional pattern, as the case may be.

[83] FIG. 8 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention, FIG. 9 and FIG. 10 are perspective views illustrating a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to one embodiment of the present invention, FIG. 11 is a sectional view taken along line I-I of FIG. 9, and FIG. 12 is a sectional view taken along line II-II of FIG. 9.

[84] The case for an electronic apparatus according to the present invention can be formed by the aforementioned ultra-speed double injection molding, and its repeated description will be omitted.

[85] Referring to FIG. 8 to FIG. 10, the case for an electronic apparatus having a display part according to this embodiment can be manufactured by the steps of forming a case body 310 through injection molding, arranging the case body 310 inside a mold, injecting a melted light-transmitting resin between the surface of the case body 310 and the mold, and forming a light-transmitting thin film injection layer 320 on the surface of the case body 310 through double injection molding by solidifying the melted light-transmitting resin, the light-transmitting thin film injection layer 320 having a protection window 322 in a single body.

[86] First of all, the case body 310 can be formed by a general injection molding for a typically opaque plastic resin. The case body 310 can be formed of an opaque material to substantially determine a background color of the product. The case body can be formed of a metal material, as the case may be, or other materials.

[87] Furthermore, a window hole 312 corresponding to the display part is formed in the case body 310. The window hole 312 is formed to have a size corresponding to the display part, and the display part can be exposed to the outside through the window hole 312. The display part means a general display means that can output various kinds of information as video information. It is to be understood that types and methods of the display part do not restrict or limit the present invention.

[88] Next, the case body 310 is arranged inside the mold. At this time, the case body 310 is arranged in such a manner that a predetermined cavity is formed between the mold and the surface of the case body 310. In this case, the case body 310 can be arranged inside the mold so that the cavity between the surface of the case body 310 and the

mold has a size of 0.2 ~ 0.6mm.

[89] A general insert process method can be used to arrange the case body 310 inside the mold. If the insert process method is used, the case body can be manufactured separately and then can be arranged inside the mold.

[90] Preferably, in order to simplify the whole manufacturing process, a double injection molding process can be used in such a manner that the case body is formed inside the mold through primary injection molding and then an upper mold required for secondary injection molding is only exchanged with another one without detaching the formed case body from the mold, so as to arrange the case body inside the mold.

[91] Subsequently, the melted light- transmitting resin is injected into a cavity between the surface of the case body 310 and the mold at high speed. In this case, high-speed injection of the light-transmitting resin means that the light-transmitting resin is injected at injection speed of 1000 mm/s or greater. Preferably, the light-transmitting resin is injected at injection speed of 1000 ~ 1500 mm/s. More preferably, the resin is injected at injection speed of 1000 ~ 1500 mm/s.

[92] Various kinds of light-transmitting resins can be used in accordance with required conditions and product options. For example, transparent resin such as acrylic resin and polycarbonate resin can be used as the light-transmitting resin. Also, opaque resin can be used as the light-transmitting resin, as the case may be.

[93] Next, a thin film injection layer 320 is formed on the surface of the case body 310 through double injection by solidifying the injected light-transmitting resin, whereby manufacture of the case can be completed. In other words, in this step, as the light- transmitting resin filled in the cavity between the surface of the case body 310 and the mold is solidified, the thin film injection layer 320 can be formed on the surface of the case body 310 in a single body with the case body 310. Also, when the light- transmitting thin film injection layer 320 is formed, the protection window 322 corresponding to the window hole 312 can be formed.

[94] Meanwhile, the case formed by the double injection molding can be noted from FIG.

9 to FIG. 12. As illustrated in FIG. 9 to FIG. 12, the light-transmitting thin film injection layer 320 which includes the protection window 322 can be formed on the surface of the case body 310 by double injection molding in a single body with the case body 310. Also, although the case body 310 and the light- transmitting thin film injection layer 320 are detached from each other in FIG. 10 for understanding of the present invention, they are substantially formed in a single body as illustrated in FIG. 9.

[95] Hereinafter, an example of a transparent light-transmitting thin film injection layer

320 having high polish will be described. In view of unique features of the light- transmitting thin film layer 320 having a light-transmitting feature, a substantial

background color of the product can be determined by the case body 310 formed of an opaque material as described above.

[96] Furthermore, it is preferable that the light-transmitting thin film injection layer 320 formed by the ultra-speed double injection molding has a thickness of 0.2 ~ 0.6mm considering strength and the whole thickness of the case. Namely, if the light- transmitting thin film injection layer 320 has a thickness less than 0.2mm, it is difficult to maintain shape strength. If the light-transmitting thin film injection layer 320 has a thickness greater than 0.6mm, the whole thickness of the case becomes thick. Accordingly, it is preferable that the thin film injection layer 320 has a thickness of 0.2 ~ 0.6mm.

[97] Moreover, a region corresponding to the protection window 322 of the light- transmitting thin film injection layer 320 is formed to have a thickness T2 relatively thicker than a thickness Tl of other regions, thereby maintaining given shape strength. For example, the thin film injection layer formed in the protection window region of the light-transmitting thin film injection layer can be located inside the window hole. In this case, the protection window region of the light-transmitting thin film injection layer 320 can be formed more thickly than the other regions as much as the depth of the window hole 312. The protection window region can be protruded to the outside of the light-transmitting thin film injection layer as the case may be.

[98] FIG. 13 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention, FIG. 14 and FIG. 15 are perspective views illustrating a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to one embodiment of the present invention, FIG. 16 is a sectional view taken along line III- III of FIG. 14, and FIG. 17 is a sectional view taken along line IV-IV of FIG. 14.

[99] The case for an electronic apparatus according to the present invention can be formed by the aforementioned ultra-speed double injection molding, and its repeated description will be omitted.

[100] Referring to FIG. 13 to FIG. 15, the case for an electronic apparatus having a camera module and a flash module according to this embodiment can be manufactured by the steps of forming a case body 410 through injection molding, arranging the case body 410 inside a mold, injecting a melted light- transmitting resin between the surface of the case body 410 and the mold, and forming a light-transmitting thin film injection layer 420 on the surface of the case body 410 through double injection molding by solidifying the melted light-transmitting resin, the light-transmitting thin film injection layer 420 having a camera lens portion 422 and a flash lens portion 424 in a single body.

[101] First of all, the case body 410 can be formed by a general injection molding for a

typically opaque plastic resin. The case body 410 can be formed of an opaque material to substantially determine a background color of the product. The case body can be formed of a metal material, as the case may be, or other materials.

[102] Furthermore, when the case body 410 is formed by injection molding, a cameral hole 412 corresponding to the camera module and a flash hole 414 corresponding to the flash module are formed in the case body 410. The camera hole 412 is formed to have a size corresponding to the camera module, and the camera module can be exposed to the outside through the camera hole 412. Likewise, the flash hole 414 is formed to have a size corresponding to the flash module, and the flash module can be exposed to the outside through the flash hole 414.

[103] In this case, the camera module means a general camera means that can take various kinds of pictures or videos, and the flash module means a general flash means that can irradiate light required for picture-taking at night or dark place. Also, it is to be understood that types and methods of the camera module and the flash module do not restrict or limit the present invention.

[104] Next, the case body 410 is arranged inside the mold. At this time, the case body 410 is arranged in such a manner that a predetermined cavity is formed between the mold and the surface of the case body 410. In this case, the case body 410 can be arranged inside the mold so that the cavity between the surface of the case body 410 and the mold has a size of 0.2 ~ 0.6mm.

[105] A general insert process method can be used to arrange the case body 410 inside the mold. If the insert process method is used, the case body can be manufactured separately and then can be arranged inside the mold.

[106] Preferably, in order to simplify the whole manufacturing process, a double injection molding process can be used in such a manner that the case body is formed inside the mold through primary injection molding and then an upper mold required for secondary injection molding is only exchanged with another one without detaching the formed case body from the mold, so as to arrange the case body inside the mold.

[107] Subsequently, the melted light-transmitting resin is injected into a cavity between the surface of the case body 410 and the mold at high speed. In this case, high-speed injection of the light-transmitting resin means that the light-transmitting resin is injected at injection speed of 1000 mm/s or greater. Preferably, the light-transmitting resin is injected at injection speed of 1000 ~ 1500 mm/s. More preferably, the resin is injected at injection speed of 1000 ~ 1500 mm/s.

[108] Various kinds of light-transmitting resins can be used in accordance with required conditions and product options. For example, transparent resin such as acrylic resin and polycarbonate resin can be used as the light-transmitting resin. Also, opaque resin can be used as the light-transmitting resin, as the case may be.

[109] Next, a thin film injection layer 420 is formed on the surface of the case body 410 through double injection by solidifying the injected light-transmitting resin, whereby manufacture of the case can be completed. In other words, in this step, as the light- transmitting resin filled in the cavity between the surface of the case body 410 and the mold is solidified, the thin film injection layer 420 can be formed on the surface of the case body 410 in a single body with the case body 410. Also, when the light- transmitting thin film injection layer 420 is formed, the camera lens portion 422 and the flash lens portion 424 respectively corresponding to the camera hole 412 and the flash hole 414 can be formed together.

[110] Meanwhile, the case formed by the double injection molding can be noted from FIG.

14 to FIG. 17. As illustrated in FIG. 14 to FIG. 17, the light-transmitting thin film injection layer 420 which includes the camera lens portion 422 and the flash lens portion 424 can be formed on the surface of the case body 410 by double injection molding in a single body with the case body 410. Also, although the case body 410 and the light-transmitting thin film injection layer 420 are detached from each other in FIG.

15 for understanding of the present invention, they are substantially formed in a single body as illustrated in FIG. 14.

[I l l] Hereinafter, an example of a transparent light-transmitting thin film injection layer 420 having high polish will be described. In view of unique features of the light- transmitting thin film layer 420 having a light-transmitting feature, a substantial background color of the product can be determined by the case body 410 formed of an opaque material as described above.

[112] Furthermore, it is preferable that the light-transmitting thin film injection layer 420 formed by the ultra-speed double injection molding has a thickness of 0.2 ~ 0.6mm considering strength and the whole thickness of the case. Namely, if the light- transmitting thin film injection layer 420 has a thickness less than 0.2mm, it is difficult to maintain shape strength. If the light-transmitting thin film injection layer 420 has a thickness greater than 0.6mm, the whole thickness of the case becomes thick. Accordingly, it is preferable that the thin film injection layer 320 has a thickness of 0.2 ~ 0.6mm.

[113] Moreover, regions corresponding to the camera lens portion 422 and the flash lens portion 424 of the light- transmitting thin film injection layer 420 are formed to have a thickness T2 relatively thicker than a thickness Tl of other regions, thereby maintaining given shape strength. For example, the camera lens region of the light- transmitting thin film injection layer 420 can be located inside the camera hole 412. In this case, the camera lens region can be formed more thickly than the other regions as much as the depth of the camera hole 412. Likewise, the flash lens region of the light- transmitting thin film injection layer 420 can be located inside the flash hole 414. In

this case, the flash lens region can be formed more thickly than the other regions as much as the depth of the flash hole 414.

[114] As described above, when the light- transmitting thin film injection layer is formed, the flash lens portion 424 can be formed. At the same time, an uneven portion 424a can be formed inside the flash lens portion 424. The uneven portion 424a allows light irradiated from the flash module to be scattered and also allows more natural illumination. In the embodiment of the present invention as aforementioned and illustrated, the uneven portion 424a includes a plurality of circles having different diameters. However, it is to be understood that the uneven portion 424a may have a wave pattern, a pyramid pattern, a lattice pattern, etc. It is also to be understood that shapes and structures of the uneven portion 424a do not restrict or limit the present invention.

[115] Meanwhile, a reflection coating part 418 can be formed near the aforementioned camera module inside or outside the light-transmitting thin film injection layer 420. The reflection coating part 418 provides a mirror surface and allows a user to take the mirror surface more conveniently during self picture-taking. Also, the reflection coating part 418 can be provided in a flat shape or a convex shape.

[116] Hereinafter, an example of the case body 410 provided with a reflection hole 416 and an example of the reflection coating part 418 formed inside the light- transmitting thin film injection layer 420 exposed to the reflection hole 416 in a flat shape will be described. In other words, the reflection hole 416 can be formed in the case body 410 when the case body 410 is formed by injection molding. After the light-transmitting thin film injection layer 420 is formed, the reflection coating part 418 can be formed inside the light-transmitting thin film injection layer 420 exposed through the reflection hole 460. If the reflection coating part 418 is formed inside the light- transmitting thin film injection layer 420, it is advantageous in that the reflection coating part 418 can be protected from scratch.

[117] Furthermore, the reflection coating part 418 can be formed of a metal material having reflection effect of light. For example, the reflection coating part 418 can be formed in such a manner that a metal thin film is formed through aluminum deposition. It is to be understood that materials and features of the reflection coating part 418 do not restrict or limit the present invention.

[118] FIG. 18 is a sectional view illustrating a structure of a case for an electronic apparatus according to another embodiment of the present invention. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts, and their detailed description will be omitted.

[119] Referring to FIG. 18, the camera lens portion 422 can be formed in the light- transmitting thin film injection layer 420 during double injection of the light-

transmitting thin film injection layer 420 in a single body with the light-transmitting thin film injection layer 420. When the light-transmitting thin film injection layer 420 is formed by double injection, an optical lens surface 423 can be formed in the camera lens portion 422 in a single body with the camera lens portion 422.

[120] In other words, the optical lens surface 423 can be formed inside the camera lens portion 422 in a single body with the camera lens portion 422 so that it can be arranged on a light path passing through the camera lens portion 422. This optical lens surface 423 can have a convex or concave spherical surface shape that can control optical features of the camera module. Alternatively, the optical lens surface 423 can have an aspherical surface shape. As described above, the optical lens surface 423 can be formed without separate process when the light-transmitting thin film injection layer 420 is formed. This structure can simplify the manufacturing process, reduce the manufacturing cost, and improve productivity.

[121] Also, although the reflection coating part is formed in the inner surface of the light- transmitting thin film injection layer in a flat shape in the embodiment of the present invention as aforementioned and illustrated, after a convex portion 417 is formed in the light- transmitting thin film injection layer 420, the reflection coating part 418 may be formed in the inner surface of the convex portion 417.

[122] In other words, the convex portion 417 may be formed in the light-transmitting thin film injection layer 420 when the light- transmitting thin film injection layer 420 is formed by double injection. After the light-transmitting thin film injection layer 420 is formed, the reflection coating part 418 may be formed in the inner surface of the convex portion 417 exposed through the reflection hole 460. The reflection coating part may be formed outside the convex portion, as the case may be. In this case, the convex portion includes circular and polygonal shapes. It is to be understood that shapes and structures of the convex portion 417 do not restrict or limit the present invention.

[123] FIG. 19 is a block diagram illustrating a method of manufacturing a case for an electronic apparatus according to one embodiment of the present invention, FIG. 20 and FIG. 21 are perspective views illustrating a case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to one embodiment of the present invention, and FIG. 22 is a sectional view taken along line V-V of FIG. 20.

[124] The case for an electronic apparatus according to the present invention can be formed by the aforementioned ultra-speed double injection molding, and its repeated description will be omitted.

[125] Referring to FIG. 19 to FIG. 21, the case for an electronic apparatus according to this embodiment can be manufactured by the steps of forming a case body 510 through

injection molding, arranging the case body 510 inside a mold, injecting a melted low hardness resin between the surface of the case body 510 and the mold, and forming a light-transmitting thin film injection layer 520 on the surface of the case body 510 through double injection molding by solidifying the melted low hardness resin.

[126] First of all, the case body 510 can be formed by a general injection molding for a transparent or opaque plastic resin. The case body 510 can be formed of a metal material, as the case may be, or other materials.

[127] Next, the case body 510 is arranged inside the mold. At this time, the case body 510 is arranged in such a manner that a predetermined cavity is formed between the mold and the surface of the case body 510. In this case, the case body 510 can be arranged inside the mold so that the cavity between the surface of the case body 510 and the mold has a size of 0.2 ~ 0.6mm.

[128] A general insert process method can be used to arrange the case body 510 inside the mold. If the insert process method is used, the case body can be manufactured separately and then can be arranged inside the mold.

[129] Preferably, in order to simplify the whole manufacturing process, a double injection molding process can be used in such a manner that the case body is formed inside the mold through primary injection molding and then an upper mold required for secondary injection molding is only exchanged with another one without detaching the formed case body from the mold, so as to arrange the case body inside the mold.

[130] Subsequently, the melted low hardness resin is injected into the cavity between the surface of the case body 510 and the mold at high speed. In this case, high-speed injection of the low hardness resin means that the low hardness resin is injected at injection speed of 1000 mm/s or greater. Preferably, the low hardness resin is injected at injection speed of 1000 ~ 1500 mm/s.

[131] Various kinds of low hardness resins can be used in accordance with required conditions and product options. For example, materials for improving feeling, i.e., rubber, urethane and silicon, which can form a soft feeling (SF) coating layer, can be used as the low hardness resin.

[132] Next, a low hardness thin film injection layer 520 is formed on the surface of the case body 510 through double injection by solidifying the injected low hardness resin, whereby manufacture of the case can be completed. In other words, in this step, as the low hardness resin filled in the cavity between the surface of the case body 510 and the mold is solidified, the low hardness thin film injection layer 520 can be formed on the surface of the case body 510 in a single body with the case body 510.

[133] The low hardness thin film injection layer 520 is advantageous in that it is convenient to maintain and manage the low hardness thin film injection layer 520 as the low hardness thin film injection layer 520 is not likely to be stained with foreign substances

such as dust and little has scratch. A substantial background color of the product can be determined by the color of the low hardness thin film injection layer 520.

[134] Also, when the low hardness thin film injection layer 520 is formed, a pattern part

522 can be formed on the surface of the low hardness thin film injection layer 520. The pattern part 522 can have an embossing shape or an engraving shape. Hereinafter, an example of the pattern part 522 having an embossing shape or an engraving shape will be described. A shape and structure of the pattern part 522, which determines background pattern of the product, can be changed depending on required conditions and design conditions. The pattern part can be provided three-dimensionally.

[135] Although the pattern part can be formed by separate process after the low hardness thin film injection layer 520 is formed, an uneven portion (not shown) corresponding to the pattern part is provided inside the mold when the low hardness thin film injection layer 520 is formed, so as to simplify the whole manufacturing process steps, whereby the pattern part can be formed simultaneously when the low hardness thin film injection layer 520 is formed.

[136] Meanwhile, the case formed by the double injection molding as above can be noted from FIG. 20 to FIG. 22. As illustrated in FIG. 20 to FIG. 22, the low hardness thin film injection layer 520 can be formed on the surface of the case body 510 by double injection molding in a single body with the case body 510. Also, although the case body 510 and the low hardness thin film injection layer 520 are detached from each other in FIG. 21 for understanding of the present invention, they are substantially formed in a single body as illustrated in FIG. 20.

[137] Furthermore, it is preferable that the low hardness thin film injection layer 520 formed by the ultra-speed double injection molding has a thickness of 0.2 ~ 0.6mm considering strength and the whole thickness of the case. Namely, if the low hardness thin film injection layer 520 has a thickness less than 0.2mm, it is difficult to maintain shape strength. If the low hardness thin film injection layer 520 has a thickness greater than 0.6mm, the whole thickness of the case becomes thick. Accordingly, it is preferable that the low hardness thin film injection layer 520 has a thickness of 0.2 ~ 0.6mm.

[138] Moreover, it is preferable that the low hardness thin film injection layer 520 is formed at a uniform thickness over the whole regions. The low hardness thin film injection layer 520 may have a locally variable thickness, as the case may be. Industrial Applicability

[139] A case for an electronic apparatus and a method of manufacturing the case for an electronic apparatus according to the present invention can be widely used in an electronic apparatus field.