Method for manufacturing a joint and joint

Abstract

To provide a method for manufacturing a joined body that prevents leakage of molding material when performing transfer molding on an insert made of multiple components, and allows for easy fixing of the molded body produced by transfer molding to other components. [Solution] A method for manufacturing a joined body, comprising: preparing a pre-molded case comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member; transferring resin onto the pre-molded case; and bringing a fourth member into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case to join the pre-molded case and the fourth member.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a bonded body and a bonded body.

Background Art

[0002] Transfer molding is mainly used for molding thermosetting resins, and involves heating and softening a material in a plunger and then pushing it through narrow passages (such as gates, sprues, runners, etc.) into the cavity of a heated mold and curing it within the mold. Transfer molding is a molding method suitable for manufacturing molded products that require high dimensional accuracy and for encapsulating coils, motors, etc. Transfer molding is also used when low-pressure encapsulation molding (encapsulation molding) is performed on electronic components such as semiconductor devices.

[0003] Patent Document 1 (Japanese Patent Laid-Open No. 8-155962) describes a rubber molding die for forming a composite body formed by fitting a metal cylinder into a molding cavity formed by overlapping a plurality of split dies, filling the molding cavity with a rubber material and vulcanizing it, and vulcanizing and adhering rubber to the outer peripheral surface of the metal cylinder. The rubber molding die is characterized in that an elastic packing is provided on the split die so as to seal between at least one end surface of the upper and lower end surfaces of the metal cylinder fitted into the molding cavity and the mold surface of each split die facing the end surface.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] When performing transfer molding on an insert made of multiple components, such as a pre-molded case in which a case component is arranged around a sealed body that is sealed with a molding material, the molding material may leak out through the gaps between the components of the insert, specifically the gap between the sealed body and the case component, under the high temperature and pressure conditions during molding.

[0006] When attaching other components to a molded body produced by transfer molding, it is common to secure the molded body to the other component using fasteners such as bolts and nuts, or adhesives. If a seal is required between the molded body and the other component, O-rings, gaskets, etc., are placed between the molded body and the other component before securing them with fasteners. In cases where adhesives are used for fastening, the adhesive may also function as a seal.

[0007] This disclosure provides a method for manufacturing a jointed body that prevents leakage of molding material when performing transfer molding on an insert made of multiple members, and allows for easy fixing of the molded body produced by transfer molding to other members. [Means for solving the problem]

[0008] This disclosure includes the following aspects: [Aspect 1] A pre-molded case is provided, comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member. Transfer molding of resin onto the aforementioned pre-molded case, The pre-molded case and the fourth member are joined by bringing the fourth member into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case. A method for manufacturing a composite body, including [the specified element]. [Aspect 2] To provide a first member having a first through hole and a second member having a second through hole, A third member is prepared with a thermoplastic material arranged around it, The third member is inserted into the first and second through holes so that the thermoplastic material is positioned between the first and second members, thereby forming a pre-molded case prototype assembly. Transfer molding a resin onto the pre-molded case prototype assembly, wherein the thermoplastic material is heated to soften or melt during the transfer molding, and the first member and the second member are pressed together with the thermoplastic material to form a pre-molded case in which at least a portion of the gap formed by the first through-hole, the second through-hole and the third member is sealed by the thermoplastic material. The pre-molded case and the fourth member are joined by bringing the fourth member into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case. A method for manufacturing a composite body, including [the specified element]. [Aspect 3] The method according to embodiment 2, wherein heating of the thermoplastic material, pressing of the first member and the second member with the thermoplastic material, or both thereof, is performed via molten resin injected during the transfer molding. [Aspect 4] The method according to any one of embodiments 1 to 3, wherein the joining of the pre-molded case and the fourth member is performed without lowering the temperature of the thermoplastic material that has protruded onto the surface of the pre-molded case after the transfer molding below its melting point. [Aspect 5] The method according to any one of embodiments 1 to 4, wherein the first member and the second member are joined together by the thermoplastic material. [Aspect 6] The method according to any one of embodiments 1 to 5, wherein the thermoplastic material mainly comprises an amorphous thermoplastic resin. [Aspect 7] The method according to embodiment 6, wherein the amorphous thermoplastic resin is at least one selected from the group consisting of thermoplastic epoxy resins and phenoxy resins, the thermoplastic epoxy resin is a polymer of (a) a bifunctional epoxy resin monomer or oligomer and (b) a bifunctional compound having two identical or different functional groups selected from the group consisting of phenolic hydroxyl groups, carboxyl groups, mercapto groups, isocyanate groups and cyanate ester groups (excluding polyhydroxy polyethers synthesized from bisphenol compounds and epichlorohydrin), and the phenoxy resin is a polyhydroxy polyether synthesized from bisphenol compounds and epichlorohydrin. [Aspect 8] The method according to embodiment 6 or 7, wherein the thermoplastic material comprises an amorphous thermoplastic resin having an epoxy equivalent of 1,600 g / eq. or more, or does not contain epoxy groups. [Aspect 9] The method according to any one of embodiments 1 to 8, wherein the first member has a convex structure around the first through hole, and the second member has a concave structure that fits into the convex structure. [Aspect 10] A pre-molded case comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member, The resin molded on the aforementioned pre-molded case, A fourth member joined to the pre-molded case via the thermoplastic resin, A composite structure including a compound. [Effects of the Invention]

[0009] According to this disclosure, a method for manufacturing a jointed body is provided that prevents leakage of molding material when performing transfer molding on an insert made of multiple members, and allows for easy fixing of the molded body produced by transfer molding to other members.

[0010] The above description should not be regarded as disclosing all embodiments of the present invention and all advantages related to the present invention.

Brief Description of Drawings

[0011] [Figure 1] It is a schematic top view and side view of a third member surrounded by a thermoplastic material. [Figure 2] It is a schematic cross-sectional view for explaining a method of manufacturing a premolded case according to an embodiment. [Figure 3] It is a schematic cross-sectional view for explaining a method of manufacturing a joined body according to the first embodiment. [Figure 4] It is a schematic cross-sectional view for explaining a method of manufacturing a joined body according to the second embodiment.

Modes for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the present invention is not limited to these embodiments only, and various applications are possible within its spirit and scope of implementation.

[0013] In the present disclosure, when using "~" for a numerical range, the numerical values at both ends are the upper limit value and the lower limit value respectively, and are included in the numerical range. When multiple upper limit values or lower limit values are described, a numerical range can be formed from all combinations of the upper limit value and the lower limit value. Similarly, when multiple numerical ranges are described, separate numerical ranges can be formed by individually selecting and combining the upper limit value and the lower limit value from these numerical ranges. Regarding the reference numerals in the drawings, elements with the same or similar numbers in different drawings indicate the same or similar elements.

[0014] In this disclosure, joining means connecting two objects together, with adhesion and welding being sub-concepts. Adhesion means bringing two adherends (objects to be joined) into a joined state via an organic material (such as a tape or adhesive, a curable resin, or a thermoplastic resin). Welding means joining by utilizing molecular diffusion, entanglement and crystallization that occurs during the process of melting the surface of a thermoplastic resin or the like with heat, followed by contact pressurization and cooling, or by utilizing intermolecular interactions with the substrate that occur during melting.

[0015] In this disclosure, "premolded case" means a component that can be used as an insert for transfer molding, wherein a case member is arranged around a component, such as a sealed body. The premolded case may come into contact with the molding material during transfer molding and may constitute part of the molded body after molding. A premolded case precursor assembly means an assembly of a group of components that form a premolded case during or after transfer molding, and includes those components that are in close proximity to each other but do not have any physical or chemical bonds between them.

[0016] [Method for manufacturing a bonded body - First embodiment] The method for manufacturing the joint of the first embodiment is: A pre-molded case is provided, comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first and second members, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member. Transfer molding of resin onto a pre-molded case, The pre-molded case and the fourth component are joined by bringing the fourth component into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case. This includes the following. According to the first embodiment, it is possible to suppress or prevent the molding material introduced into the mold under high temperature and pressure during transfer molding from leaking through the gaps between the members of the pre-molded case, and to join the pre-molded case and the fourth member via the thermoplastic material that has protruded onto the surface of the pre-molded case after transfer molding. In one embodiment, a seal of thermoplastic material is formed between the pre-molded case and the fourth member.

[0017] <Pre-molded case> A premolded case according to one embodiment includes a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first and second members, and a third member inserted through the first and second through-holes. The thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member. The premolded case of this disclosure can suppress or prevent leakage of molding material introduced into the mold under high temperature and pressure during transfer molding.

[0018] Preferably, the thermoplastic material is positioned to surround the third member along its circumferential direction, sealing at least a portion of the gap formed by the first and second through holes and the third member. More preferably, the thermoplastic material seals the entire gap formed by the first and second through holes and the third member.

[0019] 《First and Second Members》 The first and second members can be combined to form a case member for the third member. The third member is inserted through the first through-hole of the first member and the through-hole of the second member, thereby arranging the first and second members around the third member, and the third member can be supported by the first and second members.

[0020] The shapes of the first and second members are not particularly limited, as long as the first and second through holes allow the third member to be inserted into them. The first and second members may or may not have complementary shapes on their opposing surfaces. Preferably, the first member has a convex structure around the first through hole, and the second member has a concave structure that fits into the convex structure. Having such structures in the first and second members makes it easier to position the first and second members during the manufacturing of the premolded case, and further enhances the integrity of the manufactured premolded case.

[0021] Examples of materials for the first and second members include metals, inorganic materials, and resins. The materials for the first and second members may be one type or a combination of two or more types. From the viewpoint of heat resistance, the materials for the first and second members are preferably metals or inorganic materials, and from the viewpoint of strength, they are more preferably metals. If the materials for the first and second members are resins, it is desirable that the resins have a melting point or glass transition temperature at which they do not deform at the temperature during transfer molding.

[0022] Examples of metals include aluminum, iron, copper, magnesium, and titanium, and are not particularly limited. In this disclosure, single-element metal notations such as "iron" include the single-element metal and its alloys, such as iron and its alloys. Examples of iron alloys include steel and stainless steel.

[0023] Inorganic materials are not particularly limited and include, for example, glass, ceramics, and carbon molded products. Examples of glass include general glass, as well as heat-resistant glass, fire-resistant glass, fireproof glass, and chemically strengthened glass. Specific examples of chemically strengthened glass include soda-lime glass, lead glass, borosilicate glass, and quartz glass. Examples of ceramics include fine ceramics used in semiconductors, automobiles, and industrial equipment, specifically oxide ceramics such as alumina, zirconia, and barium titanate; hydroxide ceramics such as hydroxyapatite; carbide ceramics such as silicon carbide; and nitride ceramics such as silicon nitride.

[0024] Examples of resins include cured products of curable resins and high-temperature resistant engineering plastics. Examples of curable resins include at least one selected from the group consisting of epoxy resins, vinyl ester resins, and unsaturated polyester resins. Examples of high-temperature resistant engineering plastics include at least one selected from the group consisting of polyimide, polyetherimide, polysulfone, polyethersulfone, polyphenylene sulfide, and polyetheretherketone. The resin may also be a fiber-reinforced plastic (FRP) containing reinforcing fibers such as carbon fibers, glass fibers, and cellulose nanofibers.

[0025] The surfaces of the first member, the second member, or both thereof are preferably pre-treated for the purpose of removing contaminants, providing an anchoring effect, or both. Examples of pre-treatments include degreasing, UV ozone treatment, blasting, polishing, plasma treatment, corona discharge treatment, laser treatment, etching, flame treatment, and boehmite treatment. The pre-treatment may be performed by one type or a combination of two or more types. Known methods can be used as specific pre-treatment methods. Pre-treatments that clean the surface of the first member or the second member, or pre-treatments that create surface irregularities, are preferred. Specifically, if the first member or the second member contains aluminum, copper, glass, ceramic, or iron, at least one selected from the group consisting of degreasing, UV ozone treatment, blasting, polishing, plasma treatment, and etching is preferred. If the first member or the second member contains resin, at least one selected from the group consisting of degreasing, UV ozone treatment, blasting, polishing, plasma treatment, and corona discharge treatment is preferred.

[0026] Degreasing is a method of removing oil and other contaminants from the surface of the first or second component by dissolving them with organic solvents such as alcohols like ethanol or isopropanol, or ketones like acetone.

[0027] UV ozone treatment is a surface cleaning or surface modification method that utilizes the energy of short-wavelength ultraviolet light emitted from a low-pressure mercury lamp and the resulting ozone (O3). In the case of glass, it is one option for pretreatment to remove organic impurities. Generally, cleaning and surface modification equipment using low-pressure mercury lamps is called a "UV ozone cleaner," "UV cleaning equipment," or "ultraviolet surface modification equipment."

[0028] Examples of blasting processes include wet blasting, shot blasting, and sandblasting. Wet blasting can create a finely textured surface.

[0029] Polishing processes include, for example, buff polishing using abrasive cloth, roll polishing using abrasive paper such as sandpaper, and electrolytic polishing.

[0030] Plasma treatment is a method of activating a surface by exciting molecules by bombarding the surface of a first or second member with a plasma beam formed using a high-voltage power supply and a rod. An example of this is atmospheric pressure plasma treatment, which can impart hydroxyl groups or polar groups to the surface of the first or second member.

[0031] Corona discharge treatment is a method in which electrons emitted from an electrode cleave the polymer main chain or side chains near the resin surface, and the resulting radicals are used to generate hydroxyl groups or polar groups on the surface.

[0032] Laser processing is a method of changing surface properties by rapidly heating and cooling only the surface of a first or second component using laser irradiation, and is effective for roughening surfaces.

[0033] Etching processes include, for example, chemical etching processes such as the alkali method, phosphoric acid-sulfuric acid method, fluoride method, chromic acid-sulfuric acid method, and iron salt method, as well as electrochemical etching processes such as electrolytic etching.

[0034] Flame treatment is a method of hydrophilizing a surface by burning a mixture of combustion gas and air to create plasma from the oxygen in the air, and then applying the oxygen plasma to the surface of a first or second component.

[0035] Boehmite treatment is performed, for example, by treating an aluminum substrate with hot water at approximately 90-100°C, forming a boehmite (aluminum hydrated oxide) film on the surface of the aluminum substrate. Ammonia, triethanolamine, etc., may be added to the water as reaction accelerators. For example, boehmite treatment can be performed by immersing the aluminum substrate in hot water at 90-100°C containing triethanolamine at a concentration of 0.1-5.0% by mass for 3 seconds to 5 minutes. In boehmite treatment, baking is preferable after treatment with hot water to form a good boehmite film.

[0036] Thermoplastic materials The thermoplastic material contains a thermoplastic resin as its main component. The thermoplastic material is adhesive to the fourth member. Preferably, the thermoplastic material can form a seal between the pre-molded case and the fourth member. Preferably, the thermoplastic material is adhesive to the first member, the second member, or the third member, more preferably to two of the first, second, and third members, and even more preferably to all of the first, second, and third members. In this disclosure, "main component" means the component with the highest mass content among the resin components of the thermoplastic material. Preferably, the thermoplastic material contains 50% by mass or more of the resin component, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0037] It is preferable that the first member and the second member are joined together by a thermoplastic material. This eliminates the need for other means of fixing the first member and the second member together, such as fastening means like bolts and nuts.

[0038] (Amorphous thermoplastic resin) The thermoplastic material preferably contains amorphous thermoplastic resin as its main component. Amorphous thermoplastic resin refers to a resin that has no crystals, or only a small amount of crystals, and whose heat of fusion is 15 J / g or less. The heat of fusion of the amorphous thermoplastic resin is preferably 11 J / g or less, more preferably 7 J / g or less, even more preferably 4 J / g or less, and particularly preferably the melting peak is below the detection limit. By using a thermoplastic material containing amorphous thermoplastic resin with a heat of fusion of 15 J / g or less as its main component, the rapid decrease in viscosity seen in conventional crystalline hot-melt adhesives does not occur when heated, and it does not reach a low viscosity state (e.g., 0.001 Pa·s to 100 Pa·s) even in the high-temperature range exceeding 200°C. Therefore, when the thermoplastic material is heated and softened or melted and pressed against the first and second members, the thermoplastic material can be pressed against the first and second members while preventing the thermoplastic material from completely flowing out of the gap to the outside. This is advantageous in achieving high sealing performance and also contributes to increasing the joint strength of these components. Furthermore, when the thermoplastic material having the above characteristics is brought into contact with the thermoplastic material, it can maintain a thickness desirable for joining the pre-molded case and the fourth component.

[0039] The heat of fusion of amorphous thermoplastic resins is calculated from the area of ​​the endothermic peak measured by a differential scanning calorimeter (DSC) and the mass of the thermoplastic resin component. If inorganic fillers are included in the thermoplastic material, the heat of fusion is calculated from the mass of the thermoplastic resin component excluding the inorganic fillers. Specifically, the heat of fusion is calculated by weighing 2 mg to 10 mg of the sample, placing it in an aluminum pan, and heating it from 23°C to over 200°C at a rate of 10°C / min using a DSC (DSC8231 manufactured by Rigaku Corporation) to obtain a DSC curve. Then, the heat of fusion is calculated based on the area of ​​the endothermic peak at melting obtained from that DSC curve and the weighed value mentioned above.

[0040] From the viewpoint of imparting the above-mentioned properties of amorphous thermoplastic resin to a thermoplastic material, the content of amorphous thermoplastic resin in the thermoplastic material is preferably 60% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and most preferably 90% by mass or more, based on the mass of the resin component.

[0041] From the viewpoint of bonding strength with the fourth member, sealing properties, and bonding strength with the first, second, or third member, the amorphous thermoplastic resin is preferably at least one selected from the group consisting of thermoplastic epoxy resins and phenoxy resins. Thermoplastic epoxy resins and phenoxy resins have low cohesive forces within the resin and may contain hydroxyl groups, thus increasing the bonding strength with the fourth member. For similar reasons, thermoplastic epoxy resins and phenoxy resins have strong interactions with at least one of the first, second, and third members, which can further enhance sealing properties and allow these members to be bonded with higher bonding strength than conventional crystalline hot-melt adhesives.

[0042] From the viewpoint of storage stability, it is preferable that the thermoplastic material has an epoxy equivalent of 1,600 g / eq. or more, or contains an amorphous thermoplastic resin that does not contain epoxy groups. The epoxy equivalent is preferably 2,000 g / eq. or more, more preferably 5,000 g / eq. or more, even more preferably 9,000 g / eq. or more, and particularly preferably above the detection limit, meaning that epoxy groups are substantially undetectable. An epoxy equivalent above the detection limit means that when the epoxy equivalent is measured according to JIS K 7236:2001 as described below, no epoxy groups are detected.

[0043] In this disclosure, epoxy equivalent (mass of thermoplastic resin containing 1 mole of epoxy groups) is the epoxy equivalent value of the thermoplastic resin contained in the thermoplastic material, and is a value measured by the method specified in JIS K 7236:2001 (unit "g / eq."). Specifically, it is the value obtained by adding a brominated tetraethylammonium acetate solution to the thermoplastic resin and titrating it with a 0.1 mol / L perchloric acid-acetic acid solution using a potentiometric titrator. In the case of solvent-diluted products (resin varnishes), the value is calculated as a solid content equivalent from the non-volatile content. In the case of a mixture of two or more resins, it can also be calculated from the respective content and epoxy equivalent.

[0044] (Thermoplastic epoxy resin) The thermoplastic epoxy resin is preferably a polymer of (a) a difunctional epoxy resin monomer or oligomer and (b) a difunctional compound having two identical or different functional groups selected from the group consisting of phenolic hydroxyl groups, carboxyl groups, mercapto groups, isocyanate groups, and cyanate ester groups. In this disclosure, polyhydroxy polyethers synthesized from bisphenol compounds and epichlorohydrin are excluded from the thermoplastic epoxy resin. By using these compounds, polymerization reactions that form linear polymers proceed preferentially, making it possible to obtain a thermoplastic epoxy resin with desired properties.

[0045] (a) A difunctional epoxy resin monomer or oligomer means an epoxy resin monomer or oligomer having two epoxy groups in its molecule. (a) Examples of difunctional epoxy resin monomers or oligomers include bisphenol A type epoxy resin, bisphenol F type epoxy resin, difunctional phenol novolac type epoxy resin, bisphenol AD ​​type epoxy resin, biphenyl type epoxy resin, difunctional naphthalene type epoxy resin, difunctional alicyclic epoxy resin, difunctional glycidyl ester type epoxy resin (e.g., diglycidyl phthalate, diglycidyl tetrahydrophthalate, diglycidyl dimer acid ester, etc.), difunctional glycidylamine type epoxy resin (e.g., diglycidylaniline, diglycidyltoluidine, etc.), difunctional heterocyclic epoxy resin, difunctional diarylsulfone type epoxy resin, hydroquinone type epoxy resin (e.g., hydroquinone diglycidyl ether, 2 Examples include ,5-di-tert-butylhydroquinone diglycidyl ether, resorcinol diglycidyl ether, etc., difunctional alkylene glycidyl ether compounds (e.g., butanediol diglycidyl ether, butenediol diglycidyl ether, butinediol diglycidyl ether, etc.), difunctional glycidyl group-containing hydantoin compounds (e.g., 1,3-diglycidyl-5,5-dialkylhydantoin, 1-glycidyl-3-(glycidoxyalkyl)-5,5-dialkylhydantoin, etc.), difunctional glycidyl group-containing siloxanes (e.g., 1,3-bis(3-glycidoxypropyl)-1,1,3,3-tetramethyldisiloxane, α,β-bis(3-glycidoxypropyl)polydimethylsiloxane, etc.), and modified products thereof. Bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, and biphenyl type epoxy resin are preferred from the viewpoint of reactivity and workability.

[0046] Examples of the difunctional compounds having a phenolic hydroxyl group in (b) include mononuclear aromatic dihydroxy compounds having one benzene ring, such as catechol, resorcinol, and hydroquinone; bisphenol compounds such as bis(4-hydroxyphenyl)propane (bisphenol A), bis(4-hydroxyphenyl)methane (bisphenol F), and bis(4-hydroxyphenyl)ethane (bisphenol AD); compounds having a condensed ring, such as dihydroxynaphthalene; difunctional phenol compounds with an allyl group introduced, such as diallylresorcinol, diallylbisphenol A, and triallyldihydroxybiphenyl; and dibutylbisphenol A.

[0047] Examples of difunctional compounds having a carboxyl group in (b) include adipic acid, succinic acid, malonic acid, cyclohexanedicarboxylic acid, phthalic acid, isophthalic acid, and terephthalic acid.

[0048] Examples of the difunctional compounds having a mercapto group in (b) include ethylene glycol bisthioglycolate and ethylene glycol bisthiopropionate.

[0049] Examples of difunctional compounds having an isocyanate group in (b) include diphenylmethane diisocyanate (MDI), isophorone diisocyanate (IPDI), hexamethylene diisocyanate (HMDI), and tolylene diisocyanate (TDI).

[0050] Examples of difunctional compounds having the cyanate ester group of (b) include 2,2-bis(4-cyanatophenyl)propane, 1,1-bis(4-cyanatophenyl)ethane, and bis(4-cyanatophenyl)methane.

[0051] Among the difunctional compounds of (b), difunctional compounds having a phenolic hydroxyl group are preferred because they facilitate the formation of thermoplastic polymers, difunctional compounds having two phenolic hydroxyl groups and a bisphenol or biphenyl structure are preferred from the viewpoint of heat resistance and bonding properties, and at least one selected from the group consisting of bisphenol A, bisphenol F, and bisphenol S is preferred from the viewpoint of heat resistance and cost.

[0052] When (a) is a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, a bisphenol S type epoxy resin, or a biphenyl type epoxy resin, and (b) is bisphenol A, bisphenol F, or bisphenol S, the polymer obtained by polymerization of (a) and (b) has a main backbone consisting of a paraphenylene structure and ether bonds, which are linked by alkylene groups, and a side chain with hydroxyl groups generated by polyaddition. The linear structure consisting of the paraphenylene backbone increases the mechanical strength of the polymer after polymerization, and the hydroxyl groups arranged in the side chains allow for high bonding strength to the fourth member. For the same reason, sealing properties can be improved, and high bonding strength to the first, second, or third member can be achieved.

[0053] (Phenoxy resin) Phenoxy resins are polyhydroxy polyethers synthesized from bisphenol compounds and epichlorohydrin, and are thermoplastic. Methods for producing phenoxy resins include a direct reaction between a divalent phenol compound and epichlorohydrin, and an addition polymerization reaction between a diglycidyl ether of a divalent phenol compound and the divalent phenol compound. The phenoxy resin used in this disclosure can be obtained using either method. In the case of a direct reaction between a divalent phenol compound and epichlorohydrin, examples of divalent phenol compounds include phenol compounds such as bisphenol A, bisphenol F, bisphenol S, biphenol, biphenylenediol, and fluo-orangephenyl; and aliphatic glycols such as ethylene glycol, propylene glycol, and diethylene glycol. Among these, bisphenol A, bisphenol F, and bisphenol S are preferred from the viewpoint of cost, bonding properties, viscosity, and heat resistance. These may be used individually or in combination of two or more. Phenoxy resins have a chemical structure similar to epoxy resins, with a paraphenylene structure and ether bonds as the main backbone, and a structure in which these are linked together in a main chain and hydroxyl groups are arranged in the side chains.

[0054] The weight-average molecular weight of thermoplastic epoxy resins and phenoxy resins is preferably 10,000 to 500,000, more preferably 18,000 to 300,000, and even more preferably 20,000 to 200,000, based on polystyrene equivalent values ​​measured by GPC (gel permeation chromatography). The weight-average molecular weight is calculated from the elution peak positions detected by GPC and is the molecular weight value based on standard polystyrene. When the weight-average molecular weight is within the above range, a good balance between thermoplasticity and heat resistance is achieved, and a highly heat-resistant seal can be formed. When the weight-average molecular weight is 10,000 or more, it exhibits excellent heat resistance, and when it is 500,000 or less, it shows high bonding properties when melted or softened.

[0055] (Additives) If necessary, and to the extent that it does not impede the purposes of this disclosure, the thermoplastic material may contain fillers or additives as components other than the resin component.

[0056] Examples of fillers include inorganic fillers and organic fillers. Examples of inorganic fillers include spherical fused silica, metal powders such as iron powder, silica sand, talc, calcium carbonate, mica, acid clay, diatomaceous earth, kaolin, quartz, titanium dioxide, silica, phenolic resin microballoons, and glass balloons. Examples of organic fillers include resin powders.

[0057] When a thermoplastic material contains a filler, the filler content of the thermoplastic material is preferably 50% by volume or less, more preferably 30% by volume or less, even more preferably 20% by volume or less, and most preferably 10% by volume or less, based on the volume of the thermoplastic material. The resin component content of the thermoplastic material is preferably 10% by volume or more, more preferably 20% by volume or more, even more preferably 30% by volume or more, and particularly preferably 50% by volume or more, based on the volume of the thermoplastic material. In some embodiments, the resin component content of the thermoplastic material is 80% by volume or more, 90% by volume or more, or 99% by volume or more. The filler content (by volume %) is determined from the amount charged at 25°C, and specifically, it is calculated using the following formula 1 based on the specific gravity of the components other than the filler and the true specific gravity of the filler relative to the mass % of the filler. Formula 1: X=(MF / DF) / [MF / DF+(100-MF) / DR]×100% In Equation 1, X: Filler content (volume %) MF: Filler quantity (mass %) DR: Specific gravity when resin components are cured DF: True specific gravity of filler That is the case.

[0058] Examples of additives include defoaming agents, coupling agents such as silane coupling agents, pigments, and tackifying resins. Additives may be used individually or in combination of two or more. The additive content in the thermoplastic material is preferably 10% by mass or less, more preferably 5% by mass or less, and even more preferably 1% by mass or less.

[0059] 《Third component》 The third component comes into contact with the molding resin during transfer molding. It is intended that at least part or all of the third component be sealed with the molding resin. The type, size, and shape of the third component are not particularly limited.

[0060] Examples of materials for the third component include metals, inorganic materials, and resins. The material of the third component may be one type or a combination of two or more types. Exemplary metals, inorganic materials, and resins are as described with respect to the first and second components. Examples of the third component include processed ceramic components; components mainly composed of iron, aluminum, copper, or titanium; and composite materials thereof.

[0061] The surface of the third member may be pre-treated for the purpose of removing contaminants, providing an anchoring effect, or both. Examples of pre-treatments include degreasing, UV ozone treatment, blasting, polishing, plasma treatment, corona discharge treatment, laser treatment, etching, flame treatment, and boehmite treatment. Details of these pre-treatments are as described with respect to the first and second members.

[0062] <Method for manufacturing pre-molded cases> A method for manufacturing a pre-molded case according to one embodiment is: To provide a first member having a first through hole and a second member having a second through hole, A third member is prepared with a thermoplastic material arranged around it, Insert the third member into the first and second through holes such that the thermoplastic material is positioned between the first and second members, The process of heating thermoplastic materials to soften or melt them, The first and second members are pressed together with a thermoplastic material to seal at least a portion of the gap formed by the first and second through holes and the third member with the thermoplastic material. This includes the ability to manufacture the pre-molded cases mentioned above.

[0063] Hereinafter, exemplary embodiments of the manufacturing method for pre-molded cases will be described with reference to Figures 1 and 2.

[0064] The first member having the first through hole and the second member having the second through hole are as described with respect to the pre-molded case.

[0065] A thermoplastic material is placed around the third member. The third member and the thermoplastic material are as described with respect to the pre-molded case. The method of placing the thermoplastic material around the third member is not particularly limited. For example, the thermoplastic material may be in the form of a perforated film, and the third member may be inserted into the holes of the film. The thermoplastic material may be in the form of an elongated strip, and the strip may be wrapped around the third member once or multiple times. When placing the thermoplastic material, the thermoplastic material may be softened or melted by heating, and the thermoplastic material may be attached to the third member for temporary fixation. The third member and the thermoplastic material may be in contact, or the thermoplastic material may be placed away from the third member to the extent that the thermoplastic material flows and comes into contact with the third member when pressed. In this disclosure, "film" means a resin composition mainly composed of a thermoplastic resin that has been molded into a thin film.

[0066] The method for manufacturing a thermoplastic film is not particularly limited. For example, a resin composition can be obtained by heating and polymerizing the above-mentioned bifunctional epoxy resin monomer or oligomer, a solvent can be added to the obtained resin composition as needed, and the film can be applied to a release film or the like, cured and dried, and pressurized as needed to form a film. Holes can then be formed in the obtained film by punching, laser processing, or the like. Films produced by this embodiment are excellent in terms of workability and bonding properties. Films can also be produced by rolling or extruding the resin composition. The polymerization reaction may be carried out after applying the bifunctional epoxy resin monomer or oligomer to the release film, after removing the solvent to obtain the film shape, or at both stages.

[0067] Figure 1 shows schematic top view (top) and side view (bottom) of a third member 30 in which a thermoplastic material 50 is arranged around it. In Figure 1, a rectangular prism-shaped third member 30 is inserted into a hole in a rectangular film-like thermoplastic material 50, but the shape and arrangement of the third member 30 and the thermoplastic material 50 are not limited to these.

[0068] A third member is inserted into the first and second through holes such that the thermoplastic material is positioned between the first and second members. Figure 2(a) shows a first member 10 having a first through hole 12 and a convex structure 14 around the first through hole 12, and a second member 20 having a second through hole 22 and a concave structure 24 around the second through hole 22 that fits with the convex structure 14. The third member 30 is inserted into the first and second through holes 12 and 22, and the thermoplastic material 50 is positioned between the first member 10 and the second member 20. The first member 10 and the second member 20 are arranged so that the convex structure 14 and the concave structure 24 face each other.

[0069] The width of the gap formed by the first through-hole 12, the second through-hole 22, and the third member 30 is preferably such that it is at least partially closed by the thermoplastic material 50 that flows during compression. The width of the gap is, for example, 25 to 500 μm, preferably 25 to 250 μm, and more preferably 25 to 150 μm.

[0070] In an alternative embodiment, after placing the perforated thermoplastic material 50 between the first member 10 and the second member 20, the third member 30 may be inserted into the first through-hole 12, the holes in the thermoplastic material 50, and the second through-hole 22 to arrange the thermoplastic material around the third member, and simultaneously insert the third member into the first and second through-holes so that the thermoplastic material is positioned between the first and second members.

[0071] The amount of thermoplastic material 50 used should be such that it fills at least a portion of the gap formed by the first through-hole 12 and the second through-hole 22 and the third member 30, and protrudes onto the surface of the pre-molded case 1 to the extent that the fourth member 40 can be joined. The amount of thermoplastic material 50 used is such that, based on the volume of the gap, at 25°C it is, for example, 10% to 300% by volume, preferably 20% to 200% by volume, and more preferably 50% to 150% by volume. The amount of thermoplastic material 50 used may be such that a portion of the thermoplastic material 50 protrudes from the first member 10 or the second member 20.

[0072] As shown in Figure 2(b), the thermoplastic material 50 is heated to soften or melt it. The heating means are not particularly limited, and the thermoplastic material 50 can be heated using a heat source such as a heater, hot air, or infrared lamp. Alternatively, or in addition, the first member 10 or the second member 20 can be heated, and the thermoplastic material 50 can be heated by radiation from these members or by heat transfer through these members.

[0073] The thermoplastic material 50 is heated to a temperature of preferably 100°C to 300°C, more preferably 120°C to 250°C, and even more preferably 150°C to 220°C. By heating the thermoplastic material 50 to a temperature of 100°C to 300°C, the thermoplastic material 50 can be made to flow so that at least a portion of the gap is closed when pressed together.

[0074] As shown in Figure 2(c), the first member 10 and the second member 20 are pressed together with the thermoplastic material 50 to seal at least a portion of the gap formed by the first through-hole 12 and the second through-hole 22 and the third member 30 with the thermoplastic material 50. By pressing the first member 10 and the second member 20 together, the softened or molten thermoplastic material 50 is made to flow, thereby closing at least a portion of the gap with the thermoplastic material 50. This makes it possible to manufacture a pre-molded case 1 with a seal formed. It is preferable that the first member 10 and the second member 20 are joined with the thermoplastic material 50, and it is more preferable that the first member 10, the second member 20 and the third member 30 are joined to each other with the thermoplastic material 50.

[0075] The pressure applied when pressing the first member 10 and the second member 20 together is preferably 0.001 MPa to 1 MPa, more preferably 0.01 MPa to 0.5 MPa, and even more preferably 0.05 MPa to 0.2 MPa. By setting the pressure to 0.001 MPa or higher, the thermoplastic material 50 can be made to flow and block at least a portion of the gap. By setting the pressure to 1 MPa or lower, it is possible to prevent the thermoplastic material 50 from completely flowing out of the gap to the outside.

[0076] It is preferable that the thermoplastic material 50 is arranged to surround the third member 30 along its circumferential direction and seal at least a portion of the gap formed by the first through-hole 12 and the second through-hole 22 and the third member 30. It is more preferable that the thermoplastic material 50 seals all of the gap formed by the first through-hole 12 and the second through-hole 22 and the third member 30. In Figure 2(c), the thermoplastic material 50 seals a portion of the gap formed by the first through-hole 12 and the third member 30, and seals all of the gap formed by the second through-hole 22 and the third member 30. As shown in Figure 2(c), a portion of the thermoplastic material 50 may protrude from the first member 10 or the second member 20.

[0077] After compression, the thermoplastic material 50 is cooled and solidified to form the pre-molded case 1. Methods for solidifying the thermoplastic material 50 include letting it cool at room temperature or using a cooling device. From the viewpoint of ease of manufacture, letting it cool at room temperature is preferred. In this disclosure, "room temperature" means room temperature in the range of 5°C to 30°C. In this disclosure, "solidified" means solid at 23°C, that is, non-fluid under unpressurized conditions at 23°C.

[0078] <Transfer molding> The resin is transferred onto the pre-molded case described above. The apparatus and conditions for transfer molding are not particularly limited. For example, a method can be used in which the mold is opened, the pre-molded case is placed inside the mold, the mold is closed, and the thermosetting resin composition is injected from the outside into the closed mold through a hole provided in the mold, such as a sprue, and then cured. The inside of the mold may be a reduced-pressure atmosphere, or pressure may be applied from the outside of the mold. The conditions for curing the thermosetting resin composition inside the mold can be appropriately set depending on the material used. Suitable curing conditions include, for example, a temperature of 100 to 200°C, more preferably 120 to 180°C, an injection pressure of 0.1 to 10 MPa, more preferably 1 to 5 MPa, and a curing time of 1 to 30 minutes.

[0079] Figure 3 is a schematic cross-sectional view illustrating the manufacturing method of the joint according to the first embodiment, and the first embodiment is not limited to that shown in Figure 3. As shown in Figure 3(a), in the transfer molding process, molten resin 60 is brought into contact with the prepared pre-molded case 1. The resin 60 comes into contact with the thermoplastic material 50 of the pre-molded case 1 while sealing the third member 30 of the pre-molded case 1. As shown in Figure 3(b), when more resin 60 is injected into the mold, the resin 60 comes into contact with the surface of the second member 20 and spreads. At this time, a portion of the resin 60 is pushed into the gap formed by the first member 10, the second member 20 and the third member 30, causing the thermoplastic material 50 to move within the gap, and a portion of the thermoplastic material 50 protrudes to the outside from the gap. Because the thermoplastic material 50 seals the gap, leakage of the resin 60 to the outside is prevented. As shown in Figure 3(c), when the transfer molding is completed, a molded body 100 including the pre-molded case 1 and the resin 60 is formed. The excess thermoplastic material 50 is used to join with the fourth member 40.

[0080] <Joining the fourth component> As shown in Figure 3(d), the joint 110 is manufactured by bringing the fourth member 40 into contact with the thermoplastic material 50 that has protruded onto the surface of the premolded case 1, thereby joining the premolded case 1 and the fourth member 40. In the joint 110, it is preferable that the thermoplastic material 50 functions as a seal between the premolded case 1 and the fourth member 40.

[0081] 《Fourth component》 The type, size, and shape of the fourth component are not particularly limited. Examples of the fourth component include metal materials mainly composed of iron, aluminum, copper, or titanium, plastics, and ceramic materials.

[0082] Examples of materials for the fourth component include metals, inorganic materials, and resins. The material of the fourth component may be a single material or a combination of two or more materials. Exemplary metals, inorganic materials, and resins are as described with respect to the first and second components.

[0083] The surface of the fourth member may be pre-treated for the purpose of removing contaminants, providing an anchoring effect, or both. Examples of pre-treatments include degreasing, UV ozone treatment, blasting, polishing, plasma treatment, corona discharge treatment, laser treatment, etching, flame treatment, and boehmite treatment. Details of these pre-treatments are as described with respect to the first and second members.

[0084] The joining of the pre-molded case 1 and the fourth member 40 is performed by heating the thermoplastic material 50 to soften or melt it after forming the pre-molded case 1, and then pressing the fourth member 40 onto the softened or melted thermoplastic material 50. The heating means are not particularly limited, and for example, the thermoplastic material 50 can be heated using a heat source such as a heater, hot air, or infrared lamp. Alternatively or in addition, the pre-molded case 1 or the fourth member 40 can also be heated, and the thermoplastic material 50 can be heated by radiation from these members or by heat transfer through these members. It is preferable that the joining is performed without lowering the temperature of the thermoplastic material 50 that has protruded onto the surface of the pre-molded case 1 after transfer molding below its melting point. This can further reduce the time and energy costs associated with manufacturing the joined body.

[0085] The temperature of the thermoplastic material 50 during joining is preferably 100°C to 300°C, more preferably 120°C to 250°C, and even more preferably 150°C to 220°C. By setting the temperature of the thermoplastic material 50 during joining to 100°C to 300°C, high joining strength can be obtained, and in some embodiments, the sealing performance between the pre-molded case 1 and the fourth member 40 can be improved.

[0086] The pressure applied when pressing the pre-molded case 1 and the fourth member 40 together is preferably 0.001 MPa to 1 MPa, more preferably 0.01 MPa to 0.5 MPa, and even more preferably 0.05 MPa to 0.2 MPa. By setting the pressure to 0.001 MPa or higher, the thermoplastic material 50 can be spread across the joint surface, thereby increasing the joint strength. By setting the pressure to 1 MPa or lower, the thermoplastic material 50 can be held between the pre-molded case 1 and the fourth member 40.

[0087] After compression, the joint 110 is manufactured by lowering the temperature of the thermoplastic material 50 and allowing it to solidify. Methods for solidifying the thermoplastic material 50 include letting it cool at room temperature or using a cooling device. From the viewpoint of ease of manufacture, letting it cool at room temperature is preferred.

[0088] [Method for manufacturing a joint - Second embodiment] The method for manufacturing the jointed body of the second embodiment is: To provide a first member having a first through hole and a second member having a second through hole, A third member is prepared with a thermoplastic material arranged around it, A pre-molded case prototype assembly is formed by inserting a third member into the first and second through-holes such that a thermoplastic material is positioned between the first and second members, Transfer molding of resin onto a pre-molded case prototype assembly, wherein the thermoplastic material is heated to soften or melt during the transfer molding process, and the first and second members are pressed together with the thermoplastic material to form a pre-molded case in which at least a portion of the gaps formed by the first and second through holes and the third member are sealed by the thermoplastic material. The pre-molded case and the fourth component are joined by bringing the fourth component into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case. This includes the following. In the second embodiment, the pre-molded case is formed in the mold, i.e., in-situ, during or after transfer molding. This reduces the process and energy required to form the pre-molded case while suppressing or preventing the molding material introduced into the mold under high temperature and pressure during transfer molding from leaking through the gaps between the components of the pre-molded case. As a result, the process and cost required to manufacture the joined body can be reduced.

[0089] Figure 4 is a schematic cross-sectional view illustrating a method for manufacturing a molded body according to the second embodiment, and the second embodiment is not limited to that shown in Figure 4. As shown in Figure 4(a), a first member 10 having a first through hole 12, a second member 20 having a second through hole 22, and a third member 30 with a thermoplastic material 50 arranged around it are prepared. The first member 10, the second member 20, the third member 30, and the thermoplastic material 50 are as described with respect to the pre-molded case. Next, the third member 30 is inserted into the first through hole 12 and the second through hole 22 so that the thermoplastic material 50 is positioned between the first member 10 and the second member 20 to form a pre-molded case prototype assembly 2. In an alternative embodiment, a pre-molded case prototype assembly 2 may be formed by first placing a perforated thermoplastic material 50 between the first member 10 and the second member 20, and then inserting the third member 30 into the first through-hole 12, the holes in the thermoplastic material 50, and the second through-hole 22, thereby simultaneously arranging the thermoplastic material around the third member and inserting the third member into the first and second through-holes so that the thermoplastic material is positioned between the first and second members.

[0090] Next, as shown in Figures 4(b) to 4(d), the resin 60 is transfer-molded onto the pre-molded case prototype assembly 2. As shown in Figure 4(b), the thermoplastic material 50 is heated to soften or melt. Before, during, or after the softening or melting of the thermoplastic material 50, the molten resin 60 is injected into the mold and brought into contact with the pre-molded case prototype assembly 2. The thermoplastic material 50 can be heated by radiation from the heated first member 10 or second member 20, or by heat transfer through these members. Alternatively, or in addition, the thermoplastic material 50 can also be heated by utilizing the heat of the molten resin 60.

[0091] As shown in Figure 4(c), the first member 10 and the second member 20 are pressed together with the thermoplastic material 50. The resin 60 seals the third member 30, spreads upon contact with the surface of the second member 20, and comes into contact with the thermoplastic material 50. At this time, a portion of the resin 60 is pushed into the gap formed by the first member 10, the second member 20 and the third member 30, causing the thermoplastic material 50 to move within the gap, and a portion of the thermoplastic material 50 protrudes out of the gap. After pressing, the thermoplastic material 50 seals at least a portion of the gap formed by the first through hole 12 and the second through hole 22 and the third member 30, preventing the resin 60 from leaking out. At this time, the pre-molded case 1 is formed in the system.

[0092] As shown in Figure 4(d), once the transfer molding is complete, a molded body 100 including the pre-molded case 1 and resin 60 is formed. The excess thermoplastic material 50 is used to join with the fourth member 40.

[0093] The transfer molding apparatus and conditions are not particularly limited, and are the same as those described with respect to the first embodiment, except that a pre-molded case precursor assembly is placed in the mold instead of the pre-molded case.

[0094] It is preferable that the heating of the thermoplastic material, the bonding of the first and second members with the thermoplastic material, or both, be carried out via molten resin injected during transfer molding. This further reduces the time and energy costs associated with the manufacture of the joint.

[0095] As shown in Figure 4(e), the joint 110 is manufactured by bringing the fourth member 40 into contact with the thermoplastic material 50 that has protruded onto the surface of the premolded case 1, thereby joining the premolded case 1 and the fourth member 40. In the joint 110, it is preferable that the thermoplastic material 50 functions as a seal between the premolded case 1 and the fourth member 40.

[0096] The type, size, shape, material, and surface treatment of the fourth component, as well as the joining conditions between the pre-molded case 1 and the fourth component, are as described with respect to the first embodiment.

[0097] [zygote] A joint according to one embodiment includes a pre-molded case comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member; a resin molded on the pre-molded case; and a fourth member joined to the pre-molded case via the thermoplastic resin.

[0098] This invention can be used in transfer molding when manufacturing various parts used in automobiles, home appliances, machine tools, and the like.

[0099] It will be obvious to those skilled in the art that the present invention is not limited to the embodiments described above, and that various improvements and modifications of the present invention are possible without departing from the scope and spirit of the invention. [Explanation of symbols]

[0100] 1 Pre-molded case 2 Pre-molded case prototype assembly 10 First Member 12 First through hole 14 Convex structure 20 Second Member 22 Second through hole 24 Concave structure 30 Third Member 40 Fourth member 50 Thermoplastic materials 60 resin 100 molded bodies 110 Zygote

Claims

1. A pre-molded case is provided, comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member. Transfer molding of resin onto the aforementioned pre-molded case, The pre-molded case and the fourth member are joined by bringing the fourth member into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case. A method for manufacturing a composite body, including the above.

2. To provide a first member having a first through hole and a second member having a second through hole, A third member is prepared with a thermoplastic material arranged around it, The third member is inserted into the first and second through holes so that the thermoplastic material is positioned between the first and second members, thereby forming a pre-molded case prototype assembly. Transfer molding a resin onto the pre-molded case precursor assembly, wherein the thermoplastic material is heated to soften or melt during the transfer molding, and the first member and the second member are pressed together with the thermoplastic material to form a pre-molded case in which at least a portion of the gap formed by the first through hole, the second through hole and the third member is sealed by the thermoplastic material. The pre-molded case and the fourth member are joined by bringing the fourth member into contact with the thermoplastic material that has protruded onto the surface of the pre-molded case. A method for manufacturing a composite body, including the above.

3. The method according to claim 2, wherein heating of the thermoplastic material, pressing of the first member and the second member with the thermoplastic material, or both thereof, is performed via molten resin injected during the transfer molding.

4. The method according to any one of claims 1 to 3, wherein the joining of the pre-molded case and the fourth member is performed without lowering the temperature of the thermoplastic material that has protruded onto the surface of the pre-molded case after the transfer molding to below its melting point.

5. The method according to any one of claims 1 to 3, wherein the first member and the second member are joined together by the thermoplastic material.

6. The method according to any one of claims 1 to 3, wherein the thermoplastic material mainly comprises an amorphous thermoplastic resin.

7. The method according to claim 6, wherein the amorphous thermoplastic resin is at least one selected from the group consisting of thermoplastic epoxy resins and phenoxy resins, the thermoplastic epoxy resin is a polymer of (a) a bifunctional epoxy resin monomer or oligomer and (b) a bifunctional compound having two identical or different functional groups selected from the group consisting of phenolic hydroxyl groups, carboxyl groups, mercapto groups, isocyanate groups and cyanate ester groups (excluding polyhydroxy polyethers synthesized from bisphenol compounds and epichlorohydrin), and the phenoxy resin is a polyhydroxy polyether synthesized from bisphenol compounds and epichlorohydrin.

8. The method according to claim 6, wherein the thermoplastic material comprises an epoxy equivalent of 1,600 g / eq. or more, or an amorphous thermoplastic resin that does not contain epoxy groups.

9. The method according to any one of claims 1 to 3, wherein the first member has a convex structure around the first through hole, and the second member has a concave structure that fits into the convex structure.

10. A pre-molded case comprising a first member having a first through-hole, a second member having a second through-hole, a thermoplastic material interposed between the first member and the second member, and a third member inserted through the first and second through-holes, wherein the thermoplastic material seals at least a portion of the gap formed by the first and second through-holes and the third member, The resin molded on the aforementioned pre-molded case, A fourth member joined to the pre-molded case via the thermoplastic resin, A composite structure including a compound.

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