JP7724535B2 - Card case, manufacturing method of card case, and method of using high frequency welding and cutting electrode for card case - Google Patents

Description

Article 30, paragraph 2 of the Patent Act applies (1) Publication date: July 28, 2021 (2) Publication location: Aisin Shintoyo Factory Co., Ltd. (3) Discloser: Hayashi Shoten Co., Ltd. (4) Details of the disclosed invention: Hayashi Shoten Co., Ltd. disclosed to Suzuki Nami, a representative of Shinsan Shoji Co., Ltd., and Sekiguchi, a representative of Aisin Shintoyo Factory Co., Ltd., the card case, the manufacturing method for the card case, and the high-frequency welding and cutting electrode for the card case, which were invented by Hayashi Katsuhiro and for which Hayashi Katsuhiro assigned the rights to obtain the patent, and sold them to Aisin Shintoyo Factory Co., Ltd.

The present invention relates to a card case having a case surface made of a resin sheet, a method for manufacturing the card case, and a method for using a high-frequency welding/cutting electrode for the card case.

The invention of Patent Document 1 aims to provide a durable high-frequency welding and cutting device that can reliably perform welding and cutting. It is equipped with an electrode blade 20 having an electrode portion 23 that constitutes one of the electrodes and a blade portion 24 fixed integrally with the electrode portion. The high-frequency welding and cutting device performs welding and cutting simultaneously by pressing the electrode blade against a workpiece placed on a table that constitutes the other electrode. The high-frequency welding and cutting device is characterized in that the tip of the blade portion and its vicinity are plated with a material that has a lower electrical resistance than the blade portion or a material with the same electrical resistance as the electrode portion, to establish electrical conductivity between at least the tip of the blade portion and the electrode portion.

As shown in Figure 4 of Patent Document 1, in order to simultaneously weld and cut the workpiece 11, the electrode blade 20 is lowered to press the electrode portion 23 and blade portion 24 against the workpiece 11a, while a high-frequency voltage is applied to the table 1 and electrode blade 20. This causes the portion of the workpiece 11a in contact with the electrode portion 23 to be thermally welded. Meanwhile, the voltage applied by the welding and cutting device 10 is also applied to the blade portion 24 and plating, so the portion of the workpieces 11a and 11b in contact with the blade portion 24 is melted by the high frequency and then cut by the sharp tip of the blade portion 24. As described above, the workpieces 11a and 11b are simultaneously welded and cut.

In this embodiment, the blade portion 24 can be made of a material with high mechanical strength, allowing the cutting edge to be formed sharply. Furthermore, because the plating 26 applied to the blade portion 24 is electrically connected to the electrode portion 23, the portion of the workpiece 11a that contacts the cutting edge is heated by high-frequency voltage and melted while being cut by the blade portion 24, ensuring reliable fusion cutting. Furthermore, the increased durability of the blade portion 24 reduces replacement frequency and the labor required for replacement.

Japanese Patent Application Publication No. 8-267587

However, card cases manufactured using the high-frequency cutting and simultaneous welding device of Patent Document 1 have the following issues: (1) Because the right-angled lower end of the electrode portion 23 presses against the surface of the resin sheet 201 at a right angle, stress concentrates at certain points, causing the resin sheet 201 to tear and peel off (see Figure 8). (2) For the same reason, the electrode portion 23 leaves pressure marks on the surface of the resin sheet, widening the welding width and reducing the internal dimensions. This has led to a demand for wider internal dimensions for card cases of specific dimensions (see Figure 8).

In the structure of the high-frequency cutting and simultaneous welding device disclosed in Patent Document 1, the electrode blade 20 is composed of an electrode fixing arm 21, an electrode portion 23 fixed to the electrode fixing arm 21 with a bolt 22 and constituting the other electrode, a blade portion 24 fixed to the electrode fixing arm 21 while in contact with the electrode portion 23, and a spacer 25 interposed between the electrode fixing arm 21 and the electrode portion 23 and blade portion 24. The electrode portion 23 is formed from a good electrical conductor such as copper or silver. The blade portion 24 is formed from a material with excellent mechanical strength such as steel or ceramics, and its tip is formed to be extremely sharp. The blade portion 24 is plated with a material with lower electrical resistance than the blade portion 24 or a material with the same electrical resistance as the electrode portion 24 (in this embodiment, copper, silver, etc.). This structure poses a problem of the complex component configuration of the high-frequency cutting and simultaneous welding device.

The inventor therefore discovered a special structure to solve the two problems mentioned above, leading to the present invention.

In view of the above problems, the card case of the present invention 1 comprises a first sheet made of a resin suitable for high frequency welding and cutting, the first sheet having a first surface forming the front side and a second surface forming the back side, a second sheet made of a resin suitable for high frequency welding and cutting, the second sheet having the first surface forming the front side and the second surface forming the back side, a welding portion 4 welding the outer edges of the second surface of the first sheet to the second surface of the second sheet, and an insertion opening connecting the first sheet and the second sheet, through which a card can be inserted; The sheet has an opening that is welded to the end of the welded portion 4, and an opening 5 that is welded to the end of the welded portion 4, and the welded portion 4 has a band-shaped inclined surface 6 that extends diagonally and linearly from the upper end to the lower end , with the welded surface 6 forming a welded surface on the side, and a band-shaped pad portion 7 that extends laterally from the upper end of the inclined surface 6 and bulges upward from the end of the upper end surface of the first sheet 2 along the inclined surface 6, is smaller than the welded portion 4, and is continuous in a predetermined shape in a plan view.

An example of a "card case" is a case in which paper media containing product information is enclosed or inserted, and which can be used for returnable purposes.

A "card case" can be any suitable shape, such as a long, rectangular shape. For example, while a card case is basically rectangular, the shape can be modified as needed depending on the application. An example is a card case that is horizontally long and meets the standard card case dimensions (such as A4). An example is a "card case" with a thickness of 0.15 to 4 mm.

"Front" refers to the outer surface of the card case, and "back" refers to the opposite side of the "front" and the surface located in the interior area of the card case.

Examples of "resins suitable for high-frequency welding and cutting" include vinyl chloride resin, polypropylene (PP) resin, polyethylene resin, and GPET resin. GPET is a glycol-modified polyester produced by the reaction of terephthalic acid (TPA) and ethylene glycol (EG), with a certain amount of ethylene glycol (EG) replaced with cyclohexane dimethanol (CHDM).

"Resin" includes both translucent and semi-translucent materials.

It is preferable that both the first and second sheets be made of a translucent resin, but a non-translucent material may also be used. In addition to a first surface and a second surface, the first and second sheets also have side surfaces in the thickness direction.

The angle of the inclined surface of the welded portion is preferably 30 to 70 °.

The ratio of the height of the welded portion to the height of the meat reservoir portion is preferably 15 to 25 %.

The method for manufacturing a card case of the second aspect of the present invention includes a step of preparing a material for overlapping a first sheet made of a resin suitable for high-frequency welding and having a first surface forming the front and a second surface forming the back, and a second sheet made of a resin suitable for high-frequency welding and having the first surface forming the front and the second surface forming the back, and for providing an opening for connecting the first sheet and the second sheet; and a high-frequency welding and cutting step of aligning a double-edged high-frequency welding and cutting blade with specific portions of the first sheet and the second sheet so as to form an outer edge of a specific shape, and moving the blade from above to below the material placed on a table, a welding portion where the first sheet and the second sheet are welded to each other, the welding portion having an inclined surface and a fillet portion formed therein, the high-frequency welding cutting blade portion forming a pair of opposing band-shaped fillet portions, the fillet portions extending laterally from the upper end of the inclined surface and rising upward from the end of the upper end surface of the first sheet along the inclined surface, the fillet portions being smaller than the welding portion, being continuous in a predetermined shape in a plan view, and forming the band - shaped inclined surface extending obliquely linearly from the upper end to the lower end along the welded surface of the first sheet and the second sheet, the high-frequency welding cutting blade portion welding and cutting the first sheet and the second sheet to each other at the opening.

The method of using the high frequency welding and cutting electrode for the card case of the third invention comprises a conductive three-dimensional solid plate-like structure in which vertical plate materials are joined in a cross shape, a double-edged high frequency welding and cutting blade provided at the lower end of the three-dimensional solid plate-like structure, and a fixed plate material with an L-shaped or T-shaped cross section provided in a specific region on the side of the three-dimensional solid plate-like structure, wherein a through hole is provided in the specific region of the three-dimensional solid plate-like structure above the high frequency welding and cutting blade, and the fixed plate material is fastened to the through hole with a fastening member and fixed to a surface plate by the fastening member, and the card case is placed on a table. By lowering the high-frequency welding/cutting blade onto two or more overlapping resin sheets that are placed on the surface and are suitable for high-frequency welding/cutting, the resin sheets are welded and cut at the same time, thereby forming a welded portion on the resin sheets, and the welded portion has a band-shaped inclined surface that extends diagonally and linearly from the upper end to the lower end, with the welded surface forming a welded surface on the side, and a band-shaped material reservoir portion that is smaller than the welded portion and continues in a predetermined shape in a planar view, extending laterally from the upper end of the inclined surface and rising upward from the edge of the upper end surface of the resin sheet along the inclined surface.

The angle of the "high frequency welding cutting blade" is preferably 30 to 70 degrees relative to the horizontal reference plane.

The thickness of the "high-frequency welding cutting blade" is preferably 0.2 to 5 mm, and particularly 1 to 3 mm.

The inclination and height of the two blade surfaces of the "high-frequency welding cutting blade" may be arranged symmetrically with respect to the vertical center line, or may be asymmetrical.

According to inventions 1 to 3, the resin sheet is less likely to peel off because it is provided with a thick, band-shaped inclined portion extending laterally and a single linear padding portion provided at the upper end of the inclined portion and continuous with the upper end. This narrows the welding width, increasing the internal dimensions and satisfying the demand for a wider internal dimension.

According to the third aspect of the present invention, the component configuration of a high-frequency cutting and simultaneous welding device for card cases is simplified.

FIG. 1 is a front view of a card case according to an embodiment of the present invention. 1A is a cross-sectional view of the welded portion taken along line II of FIG. 1, and FIG. 1B is a cross-sectional view of the non-welded portion (with the pocket open). FIG. 2 is a perspective view of a high-frequency welding and cutting electrode of the card case according to the embodiment of the present invention. FIG. 4 is a partial enlarged view of FIG. 3 . FIG. 5 is a partially enlarged view of FIG. 4 . 1A to 1C are plan views showing a manufacturing method of a card case according to an embodiment of the present invention. 10A to 10C are explanatory diagrams showing the welding and cutting process of the card case. FIG. 1 is an explanatory diagram of welding and cutting in the prior art.

The card case 1 according to the first embodiment of the present invention will be described with reference to Figures 1 and 2.

The card case 1 of the present invention 1 comprises a first sheet 2 made of a resin suitable for high-frequency welding and cutting, having a first surface 2a forming the front surface and a second surface 2b forming the back surface; a second sheet 3 made of a resin suitable for high-frequency welding and cutting, having a first surface 3a forming the front surface and a second surface 3b forming the back surface; a welding portion 4 welding the outer edges of the second surface 2b of the first sheet 2 to the second surface 3b of the second sheet 2; an opening 5 having an insertion port through which a card can be inserted on at least one of the top end surface U, left end surface L, and right end surface R (see Figure 1) of the first sheet 2 and the second sheet 3 and welding to the end of the welding portion 4; the welding portion 4 is characterized by having an inclined surface 6 on its side that forms a welded surface; and a strip-shaped padding portion 7 that extends laterally from the upper end of the inclined surface 6 and protrudes upward from the end of the top surface of the first sheet 2, forming a continuous, predetermined shape in a plan view. Each element is explained below.

The dimensions of the card case 1 are, for example, 0.31 mm to 3.2 mm in thickness, 900 to 1800 mm in width, and 10 to 100 mm in height, but are not limited to these.

The internal dimensions of the card case 1 are, for example, 69.5 mm horizontally, with an outer horizontal dimension of 70 mm. In this case, the width of each welded portion 4 is 0.25 mm. As a comparative example, the internal dimensions are significantly larger than a card case with an outer horizontal dimension of 65 mm, an inner dimension of 60 mm, and welded portions 4 each having a width of 2.5 mm.

The first sheet 2 and second sheet 3 are made up of a front, back, and four sides, and can hold cards inside.

The thickness of the first sheet 2 is, for example, in the range of 0.2 to 1 mm, and the thickness of the second sheet 3 is, for example, in the range of 0.1 to 2 mm, and these can be set as appropriate.

The first sheet 2, second sheet 3, and opening 5 may be made of, for example, vinyl chloride resin.

The welded portion 4 is the outer edge of a U-shape where the second surface 2b of the first sheet 2 and the second surface 3b of the second sheet 2 are welded together.

The opening 5 has an insertion slot that allows a card to be inserted on at least one of the top end surface U, left end surface L, and right end surface R (see Figure 1) of the first sheet 2 and the second sheet 3, and is welded to the end of the welded portion 4.

As shown in Figure 2, the side of the welded portion 4 has an inclined surface 6 that forms the welded surface, and the material reservoir portion 7 extends laterally from the upper end of the inclined surface 6.

The angle θ of the inclined surface 6 of the welded portion 4 is 40°, for example, but is not limited to this. Peeling is less likely to occur within an appropriate range.

The material reservoir portion 7 is a continuous, band-shaped resin structure that rises to a substantially uniform height from the edge of the upper surface of the first sheet 2 and has a U-shape in plan view.

The ratio of the height of the welded portion 4 to the height of the meat reservoir portion 7 is, for example, 20%. As shown in Figure 2(a), the welded portion 4 extends up to the dotted vertical line. The area to the right of the dotted line is where the first sheet 2 and second sheet 3 are not welded, and will become the pocket (see Figure 2(b)).

The opening 5 may have an openable/closable zipper structure, such as a sliding structure that opens and closes, or a structure that opens and closes by fitting a recess and a protrusion together, but it may also be a simple opening without such a function.

The method of using the card case 1 of this embodiment of the present invention follows standard methods, so explanation will be omitted.

The high-frequency welding and cutting electrode 90 for the card case 1 will be described with reference to Figures 3 to 7. The card case produced using this electrode 90 is different from the card case 1 described above. The high-frequency welding and cutting electrode 90 comprises a conductive three-dimensional plate-like structure 92 in which vertical plate members 91 are joined in a cross shape, a high-frequency welding and cutting blade portion 93 provided at the lower end of the three-dimensional plate-like structure 92, and a fixed plate member 95 with an L-shaped or T-shaped cross section provided in a specific region of the side surface 94 of the three-dimensional plate-like structure 92. A through hole 96 is provided in a specific area of the three-dimensional plate-like structure 92 above the high-frequency welding and cutting blade portion 93, and a fixed plate material 95 is fastened to the through hole 96 with a fastening member 97, which in turn is fixed to the surface plate (not shown) of the high-frequency welder. The high-frequency welding and cutting blade portion 93 is lowered onto two or more overlapping resin sheets 101 (upper sheet 102, lower sheet 103, and having an opening 105) suitable for high-frequency welding and cutting, which are placed on a table 98 (see Figure 7), thereby welding and cutting the outer edges of the resin sheets 101 at the same time.

The angle θ of the high-frequency welding cutting blade 93 is between 40° and 70° with respect to the horizontal reference plane.

The thickness of the high-frequency welding cutting blade portion 93 is 1 to 1.4 mm.

The manufacturing method of the card case 1 of the present invention 2 will be described with reference to Figures 6 and 7.

(Step 1)
Step 1 is a step of preparing material 101, in which a first sheet 102 made of resin suitable for high-frequency welding and cutting, having a first surface forming the front side and a second surface forming the back side, and a second sheet 103 made of resin suitable for high-frequency welding and cutting, having the first surface forming the front side and the second surface forming the back side, are superimposed on each other, and an opening 105 is provided that is connected to the ends of first sheet 102 and second sheet 103.

(Step 2)
Step 2 is a high-frequency welding and cutting step. The high-frequency welding and cutting blade 93 is moved from top to bottom, aligned with specific portions of the first sheet 102 and the second sheet 103, to form the outer edge of the specific shape shown in the figure. High-frequency current flows throughout the three-dimensional plate-like structure 92, and simultaneous welding and cutting are performed at the points where the material comes into contact. The details of this step are as follows:

(Step 2-1)
The high frequency welding cutting blade 93 welds the first sheet 102 and the second sheet 103 together, and the high frequency welding cutting blade 93 forms a pair of opposing linear small padding portions 107a (see FIG. 7B).

(Step 2-2)
The inclined surface 6 is provided along the fused surfaces of the first sheet 102 and the second sheet 103, and forms a band-like surface that extends obliquely from the upper end to the lower end of the fused surfaces.

(Step 2-3)
The high frequency welding cutting blade 93 cuts off the lower ends of the first sheet 102 and the second sheet 103 (FIG. 7(c)).

(Step 2-4)
An opening 5 is formed on the upper end surface U other than the welded portion 4, serving as an insertion opening through which a card can be inserted.

As described above, according to embodiments 1 to 3 of the present invention, the card case is provided with a thick, laterally extending inclined surface 6 and a single, linear padding portion 7 provided at the upper end of the inclined surface 6 and continuing from the upper end, making it difficult for the first sheet 2 and second sheet 3 to peel off. The width of the welded portion 4 is narrowed, increasing the internal dimensions and satisfying the desire for a wider internal dimension. Welding irregularities are less likely to occur, making it easier to adjust the position of the card case material, improving productivity. Processing loss is also reduced.

According to the third embodiment of the present invention, the component configuration of the high-frequency cutting and simultaneous welding device for the card case 1 is simplified.
It's effective.

The present invention is not limited to the above-described embodiment, and modifications can be made without departing from the technical spirit of the present invention. These modifications and equivalents are also included within the technical scope of the present invention. For example, the card case 1 may be made of multiple layers, for example, three or more layers, in order to perform high-frequency welder processing.

The present invention can provide a card case that is less likely to tear and has increased internal dimensions. Furthermore, by simplifying the high-frequency welding and cutting electrode and welding using the angle formed in the high-frequency welding cutting blade, it is possible to weld difficult-to-process materials, such as hard materials together or soft and hard materials, in a fluid, continuous manner as the materials melt, rather than in stages, making it highly valuable for industrial applications.

1 Card case 2 First sheet 3 Second sheet 4 Welding portion 5 Opening 6 Inclined surface 7 Filler reservoir 90 High frequency welding/cutting electrode 91 Plate material 92 Three-dimensional plate-like structure 93 High frequency welding/cutting blade 94 Side surface 95 Fixed plate material 96 Through hole 97 Fastening member 98 Table 101 Resin sheet 101 Material 102 Resin sheet 103 Resin sheet 105 Opening 107a Small filler reservoir 201 Resin sheet (prior art)
L Left end surface R Right end surface U Upper end surface W Thickness θ Angle

Claims (7)

a first sheet made of a resin suitable for high frequency welding and cutting, the first sheet having a first surface forming a front surface and a second surface forming a back surface;
a second sheet made of a resin suitable for high frequency welding and cutting, the second sheet having a first surface forming a front surface and a second surface forming a rear surface;
a welding portion welding an outer edge portion of the second surface of the first sheet to the second surface of the second sheet;
a slot that connects the first sheet and the second sheet and allows a card to be inserted, and an opening that is welded to an end of the welded portion;
The welded portion is
A band-like inclined surface extending diagonally and linearly from the upper end to the lower end , which becomes a melting surface on the side,
a strip-shaped pad portion extending laterally from an upper end of the inclined surface and rising upward from an end of the upper end surface of the first sheet along the inclined surface , the pad portion being smaller than the welded portion and having a predetermined continuous shape in a plan view;
A card case comprising: 2. The card case according to claim 1, wherein the ratio of the height of the welded portion to the height of the padded portion is 15 to 25 %. 3. The card case according to claim 1, wherein the angle of the inclined surface of the welded portion is 30 to 70 degrees. a step of preparing a material for overlapping a first sheet made of a resin suitable for high frequency welding and cutting, the first sheet having a first surface forming a front surface and a second surface forming a rear surface, and a second sheet made of a resin suitable for high frequency welding and cutting, the second sheet having the first surface forming a front surface and the second surface forming a rear surface, and providing an opening for connecting the first sheet and the second sheet;
a high-frequency welding and cutting process in which a double-edged high-frequency welding and cutting blade is aligned with specific portions of the first sheet and the second sheet so as to form an outer edge portion of a specific shape, and is moved from above to below the material placed on a table,
By the high frequency welding and cutting process, an inclined surface and a recessed portion are formed in the welding portion where the first sheet and the second sheet are welded,
the high-frequency welding cutting blade portion forms a pair of opposing band-shaped recessed portions, the recessed portions extend laterally from the upper end of the inclined surface, and rise upward from the end of the upper end surface of the first sheet along the inclined surface, are smaller than the welded portion, and are continuous in a predetermined shape in a plan view;
forming a band- like inclined surface that extends obliquely linearly from the upper end to the lower end along the fusion surfaces of the first sheet and the second sheet, the inclined surface being the fusion surface;
A method for manufacturing a card case, characterized in that the high-frequency welding and cutting blade welds and cuts the first sheet, the second sheet, and the opening. a conductive three-dimensional plate-like structure in which vertical plate members are joined in a cross shape;
a double-edged high-frequency welding and cutting blade provided at a lower end of the three-dimensional plate-like structure;
A fixed plate member having an L-shaped or T-shaped cross section, which is provided in a specific region of a side surface of the three-dimensional plate-like structure;
Equipped with
a method for using a high-frequency welding and cutting electrode for a card case, the method comprising: providing a through hole in a specific region of the three-dimensional plate-like structure above the high-frequency welding and cutting blade portion; and fastening the fixed plate material to the through hole with a fastening member and fixing the fixed plate material to a base plate by the fastening member; lowering the high-frequency welding and cutting blade portion onto two or more overlapping resin sheets suitable for high-frequency welding and cutting placed on a table to weld and cut the resin sheets at the same time, thereby forming a weld portion in the resin sheets, the weld portion having a band-like inclined surface that extends obliquely and linearly from the upper end to the lower end, and that forms a weld surface on its side; and providing a band-like material reservoir portion that is smaller than the weld portion and that continues to have a predetermined shape in a plan view, the band-like inclined surface extending diagonally and linearly from the upper end of the inclined surface and that protrudes upward from the edge of the upper end surface of the resin sheet along the inclined surface. 6. The method for using the high frequency welding/cutting electrode for a card case according to claim 5, wherein the angle of the high frequency welding/cutting blade portion is 30 ° to 70 ° with respect to a horizontal reference plane. 7. The method for using the high frequency welding/cutting electrode for a card case according to claim 5 or 6, wherein the high frequency welding/cutting blade portion has a thickness of 0.2 to 5 mm.