Method for manufacturing a metal-resin composite

Abstract

The present invention provides an apparatus and a method for manufacturing a metal resin composite. The apparatus (50) is an apparatus for manufacturing a metal resin composite (1) by press forming a metal plate (10) and a resin material (20). The apparatus (50) includes: an upper die (110) and a lower die (120) that sandwich the metal plate (10) and the resin material (20); and an elastic member (124) that is installed to a molding surface of the lower die (120). A cavity (C) for arranging the resin material (20) is provided by the upper die (110) and the lower die (120). The elastic member (124) is arranged to enclose the resin material (20) in the cavity (C) by pushing the metal plate (10) against the upper die (110).

Description

TECHNICAL FIELD

[0001] The present application relates to an apparatus and a method for manufacturing a metal resin composite. BACKGROUND

[0002] An apparatus for press-molding a metal member and a resin material having a thermosetting property to manufacture a metal resin composite is known (for example, Patent Literature 1).

[0003] PRIOR ART DOCUMENTS

[0004] PATENT LITERATURE

[0005] Patent Literature 1: Japanese Patent Application Publication No. 2020-104411 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] In the case of press-molding a metal resin composite, it is difficult to close the gap between the upper die and the lower die compared to the case of press-molding only a resin material. As a result, it is possible that the resin material leaks out to unintended portions through the gap between the upper die and the lower die of the mold. Such leakage of the resin material involves, for example, problems of poor spot welding in a subsequent assembly process, mold seizure due to inflow of the resin material to other gaps of the mold, or unfilling due to insufficient filling pressure of the resin material.

[0008] The present application relates to an apparatus and a method for manufacturing a metal resin composite.

[0009] MEANS FOR SOLVING THE PROBLEMS

[0010] A first aspect of the present application provides an apparatus for press-molding a metal member and a resin material to manufacture a metal resin composite, comprising: an upper die and a lower die that sandwich the metal member and the resin material; and an elastic member installed on a molding surface of the lower die, wherein a chamber for arranging the resin material is provided by the upper die and the lower die, and the elastic member is arranged to enclose the resin material in the chamber by pushing the metal member against the upper die.

[0011] According to this structure, since the metal member is pushed against the upper die by the elastic member, the resin material is enclosed in the chamber. Therefore, leakage of the resin material from the chamber can be suppressed, and leakage of the resin material to unintended portions can be suppressed. By suppressing the leakage of the resin material, the filling pressure of the resin material in the chamber becomes high, and stable molding of the resin material can be achieved. Thus, a metal resin composite of stable quality can be manufactured.

[0012] The metal resin composite can have a bottom wall portion extending in a horizontal direction, a side wall portion rising from both ends of the bottom wall portion, and a flange portion extending outward from the side wall portion in the horizontal direction in a cross section perpendicular to the length direction. The upper mold can have a first upper molding surface that molds the bottom wall portion, a second upper molding surface that molds the side wall portion, and a third upper molding surface that molds the flange portion in the cross section. The lower mold can have a first lower molding surface that molds the bottom wall portion, a second lower molding surface that molds the side wall portion, and a third lower molding surface that molds the flange portion in the cross section.

[0013] According to this structure, the cross-sectional shape of the metal resin composite is molded in a hat shape. The metal resin composite in a hat shape is highly versatile and can be used in a variety of applications.

[0014] A step difference can be provided in the second upper molding surface.

[0015] According to this structure, the resin material needs to flow over the step difference of the upper mold in order to leak out of the cavity, so the leakage of the resin material can be suppressed. Thus, the filling pressure in the cavity of the resin material can be increased, and the quality can be improved.

[0016] A holding groove for holding the elastic member can be provided in the second lower molding surface. The thickness of the elastic member can be greater than the depth of the holding groove.

[0017] According to this structure, the elastic member can be held by the holding groove, so the elastic member can be easily positioned and the movement of the elastic member during molding can be restricted. Furthermore, since the elastic member protrudes from the second lower molding surface, it is sandwiched by the upper mold (specifically, the metal member) and the lower mold and is subjected to a compressive force. Thus, the effectiveness of the sealing function of the elastic member can be improved.

[0018] The holding groove can have a shape in which the bottom portion is wider than the width of the opening portion in the cross section.

[0019] According to this structure, since the elastic member is caught in the holding groove, the elastic member can be suppressed from falling out of the holding groove. During press molding, the elastic member is deformed to match the shape of the holding groove under pressure, so the effect of suppressing the elastic member from falling out can be exerted regardless of the shape of the elastic member.

[0020] The holding groove can be disposed at the same height position as the step difference or a position higher than the step difference in the cross section when the upper mold and the lower mold are closed.

[0021] According to this structure, the metal member is pushed against the upper mold at the same height position as the step or at a position higher than the step by the elastic member, so the resin material is enclosed at a position lower than the step. Therefore, the resin material can be further inhibited from flowing over the step of the upper mold, and the filling pressure of the resin material in the cavity can be further increased, and the quality can be improved. Here, the retaining groove is arranged at the same height position as the step means that the retaining groove and the step are arranged so as to overlap in the height direction (up-down direction). Further, the retaining groove is arranged at a position higher than the step means that the retaining groove and the step are arranged so as not to overlap in the height direction (up-down direction), and the retaining groove is positioned above the step.

[0022] Also, the end portion of the elastic member protruding from the retaining groove in the cross section can be chamfered or have a shape with roundness.

[0023] According to this structure, the end portion of the elastic member protruding from the retaining groove can be inhibited from being deformed so as to spread along the second molding lower surface and unintentionally caught between the metal member and the lower mold. Thus, damage or mold sticking (abnormal wear) of the elastic member can be inhibited. In detail, mold sticking (abnormal wear) caused by excessive increase in the compression force between the upper mold and the metal member can be inhibited.

[0024] Also, the end portion of the elastic member inserted into the retaining groove in the cross section can be chamfered or have a shape with roundness.

[0025] According to this structure, a deformation allowance (deformation margin) of the elastic member can be ensured in the retaining groove. If there is no deformation allowance of the elastic member, a very high pressure acts on the elastic member, and mold sticking can occur. In detail, mold sticking (abnormal wear) caused by excessive increase in the compression force between the upper mold and the metal member can be inhibited.

[0026] A second aspect of the present application provides a method for manufacturing a metal resin composite by pressure molding a metal member and a resin material, the method including: sandwiching the metal member and the resin material by an upper mold and a lower mold; pushing the metal member against the upper mold by an elastic member via the sandwiching, and enclosing a cavity formed by the upper mold and the lower mold; and integrating the metal member and the resin material by the pressure molding while enclosing the resin material in the cavity.

[0027] According to this method, the metal member is pushed against the upper mold by the elastic member, and the resin material is enclosed in the cavity. Therefore, the resin material can be inhibited from leaking from the cavity, and the resin material can be inhibited from leaking to unintended portions. By inhibiting the leakage of the resin material, the filling pressure of the resin material in the cavity is increased, and stable molding of the resin material can be achieved. Thus, a metal resin composite of stable quality can be manufactured.

[0028] Also, the aforementioned method can further include, before integrating the aforementioned metal member and the aforementioned resin material by means of the aforementioned press forming, press forming only the aforementioned metal member into a hat shape.

[0029] According to this method, since the metal member is press formed alone, the forming precision can be improved. Furthermore, the metal resin composite in a hat shape is highly versatile, and can be used in a variety of applications.

[0030] Effects of Invention

[0031] According to the present invention, in the device and method for manufacturing a metal resin composite, the leakage of the resin material to unintended portions can be suppressed. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 is a cross-sectional view of a metal resin composite.

[0033] Figure 2 is a cross-sectional view showing a first step of a method for manufacturing a metal resin composite according to a first embodiment.

[0034] Figure 3 is a cross-sectional view showing a second step of a method for manufacturing a metal resin composite according to the first embodiment.

[0035] Figure 4 is a cross-sectional view showing a third step of a method for manufacturing a metal resin composite according to the first embodiment.

[0036] Figure 5 is a cross-sectional view showing a fourth step of a method for manufacturing a metal resin composite according to the first embodiment.

[0037] Figure 6 is a cross-sectional view showing a fifth step of a method for manufacturing a metal resin composite according to the first embodiment.

[0038] Figure 7 is a cross-sectional view showing a portion of a dashed circle VII of Figure 6 enlarged.

[0039] Figure 8 is a cross-sectional view showing a first modification of Figure 7 .

[0040] Figure 9 is a cross-sectional view showing a second modification of Figure 7 .

[0041] Figure 10 is a cross-sectional view showing a third modification of Figure 7 .

[0042] Figure 11 is a sectional view showing a 4th modification of Figure 7

[0043] Figure 12 is a sectional view showing a 5th modification of Figure 7

[0044] Figure 13 is a sectional view showing a 6th modification of Figure 7

[0045] Figure 14 is a sectional view showing a 7th modification of Figure 7

[0046] Figure 15 is a sectional view showing a 5th process of a method for manufacturing a metal resin composite of the 2nd embodiment.

[0047] Figure 16 is a sectional view showing a 2nd process of a method for manufacturing a metal resin composite of another modification. DETAILED DESCRIPTION

[0048] Hereinafter, referring to the drawings, a device and a method for manufacturing a metal resin composite will be described as an embodiment of the present application.

[0049] (1st Embodiment)

[0050] Referring to Figure 1 , a metal resin composite 1 manufactured in the present embodiment includes a metal plate (metal member) 10 and a resin material 20. The metal resin composite 1 has a hat shape in a cross section perpendicular to a length direction. In detail, the metal resin composite 1 is configured by adhering the resin material 20 to an inner surface (concave surface) of the metal plate 10 having a hat shape. However, the shape of the metal resin composite 1 is not limited to the hat shape, and can be any shape.

[0051] The metal resin composite 1 has a bottom wall portion 2 extending in a horizontal direction, side wall portions 3 rising from both ends of the bottom wall portion 2, and a flange portion 4 extending from the side wall portions 3 to the outside in the horizontal direction. The bottom wall portion 2 is configured by the metal plate 10 and the resin material 20, the side wall portions 3 are configured by the metal plate 10 and the resin material 20, and the flange portion 4 is configured by only the metal plate 10. The resin material 20 ends at an end surface 20a on the way from the bottom wall portion 2 toward the flange portion 4 in the side wall portions 3.

[0052] Referring to Figures 2-6 ​​​​The device 50 and the method for manufacturing the metal resin composite 1 according to the present embodiment will be described. In the drawings, the horizontal direction is indicated as the X direction, and the vertical direction (the up-down direction or the height direction) is indicated as the Y direction. Further, the cross-sectional lines indicating that the section is given to the metal resin composite 1 (the metal plate 10 and the resin material 20) and the elastic member 124 described later, but the cross-sectional lines are omitted for other members in order to make the drawing clear.

[0053] In the present embodiment, the press forming is performed twice in the process of sequentially performing the 1st to 5th processes shown in Figures 2-6 The 1st press forming is performed in the 1st to 3rd processes shown in Figures 2-4 The 2nd press forming is performed in the 3rd to 6th processes shown in Figures 4-6 In the present embodiment, the 1st and 2nd press formings are performed with the same mold 100, but the 1st and 2nd press formings can be performed with separate molds. Further, the metal resin composite 1 can be produced one by one, that is, the 1st press forming and the 2nd press forming can be performed continuously. Alternatively, the integrated forming of the metal plate 10 and the resin material 20 (the 2nd press forming) can be repeatedly performed after the forming of the metal plate 10 (the 1st press forming) is repeatedly performed by the number of pieces required. Further, as will be described later in detail, there is a time for setting the resin material 20 to the metal plate 10, and a time for disassembling the elastic member 124, so the latter is more preferable from the viewpoint of shortening these times.

[0054] The device 50 for manufacturing the metal resin composite 1 according to the present embodiment has the mold 100, the driving unit 130 that drives the mold 100, and the heating unit 140 that heats the mold 100. Further, the driving unit 130 and the heating unit 140 can use a publicly known structure capable of performing the press forming, and are not illustrated in detail but are indicated as conceptual diagrams in Figure 2 , and the subsequent drawings are omitted. Figure 3

[0055] The mold 100 is a structure that press forms the metal plate 10 and the resin material 20 to manufacture the metal resin composite 1. The mold 100 has an upper mold 110 and a lower mold 120 that sandwich the metal plate 10 and the resin material 20. In the present embodiment, the upper mold 110 is configured as a punch, and the lower mold 120 is configured as a die. The upper mold 110 is configured to be movable in the vertical direction by the driving unit 130, that is, to be approachable and distanced from the lower mold 120. However, the driving form of the mold 100 by the driving unit 130 is not particularly limited, and the driving unit 130 can be a structure that moves at least one of the upper mold 110 and the lower mold 120 in the vertical direction.

[0056] ​The upper mold 110 has a bottom wall portion 2 (see reference) Figure 1 The first formed upper surface 111, the side wall portion 3 (refer to) Figure 1 The second shaped upper surface 112, and the flange portion 4 (refer to) Figure 1 The third molded upper surface 113 is formed. In this embodiment, the first molded upper surface 111 and the third molded upper surface 113 are configured as horizontal planes, and the second molded upper surface 112 connects the first molded upper surface 111 and the third molded upper surface 113 and is formed by tilting from the vertical direction.

[0057] In this embodiment, a step 112a is provided on the second molding upper surface 112. The step 112a is provided such that it increases by one step from the first molding upper surface 111 toward the third molding upper surface 113.

[0058] The lower mold 120 has a bottom wall portion 2 (see reference) Figure 1 The first formed lower surface 121, the side wall portion 3 (refer to) Figure 1 The second lower surface 122 formed by forming, and the flange portion 4 (refer to) Figure 1 The third lower molded surface 123 is formed. In this embodiment, the first lower molded surface 121 and the third lower molded surface 123 are configured as horizontal planes, and the second lower molded surface 122 connects the first lower molded surface 121 and the third lower molded surface 123 and is configured to be inclined in the vertical direction. The first lower molded surface 121 is arranged opposite to the first upper molded surface 111, the second lower molded surface 122 is arranged opposite to the second upper molded surface 112, and the third lower molded surface 123 is arranged opposite to the third upper molded surface 113.

[0059] In this embodiment, a retaining groove 122b is provided on the second molded lower surface 122. The retaining groove 122b is a recess for retaining the elastic member 124 (described later), and has a depth in the vertical direction from the second molded lower surface 122. However, the retaining groove 122b is not a necessary structure and can be omitted if needed.

[0060] exist Figure 2 In the first step shown, the upper mold 110 and lower mold 120 are heated by the heating unit 140 to prepare for warm pressing. Furthermore, the flat metal plate 10, before forming, is placed on the lower mold 120. Here, the forming of the metal plate 10 (first pressing) can be performed using either warm or cold pressing. However, from a production efficiency point of view, it is preferable to perform the forming of the metal plate 10 (first pressing) using warm pressing when performing the first and second pressings consecutively as described above.

[0061] exist Figure 3In the second process shown, the upper mold 110 is lowered, the metal plate 10 is sandwiched by the upper mold 110 and the lower mold 120, and is press-formed into a substantially hat shape. In a state where the upper mold 110 and the lower mold 120 are closed, the distance dl between the first forming upper surface 111 and the first forming lower surface 121 is larger than the thickness t of the metal plate 10 (dl > t), and the distance d3 between the third forming upper surface 113 and the third forming lower surface 123 is substantially equal to the thickness t of the metal plate 10 (d3 = t). Further, the distance d21 between the second forming upper surface 112 below the step 112a and the second forming lower surface 122 is larger than the thickness t of the metal plate 10 (d21 > t), and the distance d22 between the second forming upper surface 112 above the step 112a and the second forming lower surface 122 is substantially equal to or slightly larger than the thickness t of the metal plate 10 (d22 = t or d22 > t). In particular, by setting the distance d22 to be equal to the thickness t of the metal plate 10, the filling pressure of the resin material 20 in the subsequent process can be increased. In addition, in this process, the resin material 20 (see Figures 4-6 ) has not yet been filled, and only the metal plate 10 is sandwiched by the upper mold 110 and the lower mold 120. In a state where the upper mold 110 and the lower mold 120 are closed, between the first to second forming upper surfaces 111 to 112 and the first to second forming lower surfaces 121 to 122 (in detail, the metal plate 10), a chamber C for filling the resin material 20 is provided.

[0062] In Figure 4 the third process shown, the upper mold 110 is raised. At this time, the metal plate 10 is formed into a substantially hat shape close to the final shape (see Figure 1 ). After the upper mold 110 is raised, in order to perform the second pressurization, an elastic member 124 is attached to the holding groove 122b of the lower mold 120. The elastic member 124 has elasticity, for example, is composed of silicone rubber. In the present embodiment, the elastic member 124 is a cuboid shape extending along the holding groove 122b, and Figure 4The cross-section is rectangular. The elastic member 124 is configured to enclose the resin material 20 within the chamber C. The elastic member 124 protrudes from the second molding lower surface 122 while mounted in the retaining groove 122b. After the elastic member 124 is installed, a sheet of resin material 20 (also called a prepreg) cut to the required size is placed on the metal plate 10. In this embodiment, the resin material 20 is cured under high temperature and pressure using a molding method called SMC (Sheet Molding Compound) (see step 4 described later). In this embodiment, fiber-reinforced plastic (FRP) is used as the resin material 20, which is formed by impregnating glass fibers or carbon fibers with resin. Furthermore, in this embodiment, the resin material 20 is thermosetting. In this step, the resin material 20 has not yet been heated, i.e., it has not been cured. In addition, the resin material 20 does not need to be sheet-like and can be of any shape.

[0063] exist Figure 5 In the fourth step shown, the upper mold 110 is lowered, and the metal plate 10 and resin material 20 are clamped together by the upper mold 110 and the lower mold 120, and pressure-formed into a complete hat shape. In this embodiment, the elastic member 124 is installed at a position higher than the step difference 112a when the upper mold 110 and the lower mold 120 are closed (see reference). Figure 5 The elastic member 124 seals the resin material 20 within the cavity C by pressing the metal plate 10 against the upper mold 110 (particularly the second forming upper surface 112 above the step 112a). Thus, using the SMC method, resin material 20 cut to the required size is fed into the mold 100 and cured under high temperature and pressure. In this embodiment, the cavity C refers to the space below the step 112a formed by the upper mold 110 and the lower mold 120 (specifically, the metal plate 10). The resin material 20 is heated within the cavity C and does not leak out, but rather cures. At this time, the resin material 20 abuts against the step 112a at its end face 20a.

[0064] exist Figure 6 In the fifth step shown, the upper mold 110 is raised. The metal plate 10 is formed into its final shape (a hat shape in this embodiment), and the resin material 20 is fixed to the upper surface of the metal plate 10 (the concave surface of the hat shape), forming a metal-resin composite 1. Furthermore, the elastic member 124 recovers its original shape due to its elasticity and can be reused. Preferably, the elastic member 124 has sufficient resistance to heat from the heating element 140 (see reference 140). Figure 2 The heat resistance of heating.

[0065] Figure 7 It isFigure 6 a cross-sectional view of the portion of the broken line circle VII.

[0066] In the present embodiment, the holding groove 122b is provided at a position 6 mm away downward from the 3rd formed lower surface 123 (D1 = 6 mm). The corner portion that becomes the boundary of the 2nd formed lower surface 122 and the 3rd formed lower surface 123 is composed of a curved surface with a radius of 5 mm. The holding groove 122b is not provided at this corner portion, but is provided at the 2nd formed upper surface 112. The holding groove 122b has a depth D2 of 4 mm and a width D3 of 5 mm.

[0067] In the present embodiment, the elastic member 124 is a square of 5 mm on one side in a cross section of the holding groove 122b. Figure 7 Thus, the elastic member 124 protrudes by 1 mm (T = 1 mm) from the holding groove 122b. That is, the thickness (T + D2) of the elastic member 124 is thicker than the depth D2 of the holding groove 122b by the thickness T.

[0068] As described later, the shape of the holding groove 122b and the elastic member 124 is not limited to the above, but can be various.

[0069] According to the present embodiment, since the metal plate 10 is pushed against the upper mold 110 by the elastic member 124, the resin material 20 is enclosed in the cavity C. Therefore, the leakage of the resin material 20 from the cavity C can be suppressed, and the leakage of the resin material 20 to unintended portions (for example, the flange portion 4, etc.) can be suppressed. By suppressing the leakage of the resin material 20, the filling pressure of the resin material 20 in the cavity C becomes high, and stable molding of the resin material 20 can be achieved. Thus, a metal resin composite 1 of stable quality can be manufactured.

[0070] Further, in the present embodiment, the cross-sectional shape of the metal resin composite 1 is molded into a hat shape. The hat-shaped metal resin composite 1 is highly versatile, and can be used in various uses.

[0071] Further, the resin material 20 needs to flow over the step 112a of the upper mold 110 in order to leak from the cavity C, so the leakage of the resin material 20 can be suppressed. Thus, the filling pressure of the resin material 20 in the cavity C can be increased, and the quality can be improved.

[0072] Further, in the present embodiment, since the elastic member 124 can be held by the holding groove 122b, the elastic member 124 can be easily positioned and movement of the elastic member 124 in the molding can be restricted. Further, since the elastic member 124 protrudes from the second molding lower surface 122, the elastic member 124 is sandwiched by the upper die 110 (in detail, the metal plate 10) and the lower die 120 and receives a compression force. Thus, effectiveness of the sealing function of the elastic member 124 can be improved. In addition, the example in which the elastic member 124 is composed of silicone rubber is shown in the above, but instead, an elastic member such as a corrugated plate made of metal can be used.

[0073] Figure 8 is a cross-sectional view showing a first modification of Figure 7

[0074] The elastic member 124 of the first modification protrudes from the holding groove 122b in the illustrated cross section. The end portion 124a protruding from the holding groove 122b is chamfered in the first modification. The chamfering is, for example, a bevel chamfer (Cchamfer) having a chamfer angle of 45°.

[0075] Figure 9 is a cross-sectional view showing a second modification of Figure 7

[0076] In the second modification, the elastic member 124 has a rounded shape in the illustrated cross section at the end portion 124a protruding from the holding groove 122b. The rounded shape is, for example, a semicircular shape in the illustrated cross section.

[0077] According to the first and second modifications, the end portion 124a protruding from the holding groove 122b can be inhibited from being deformed in a manner to spread along the second molding lower surface 122 and unintentionally sandwiched between the metal plate 10 and the lower die 120. Thus, damage or die sticking (abnormal wear) of the elastic member 124 can be inhibited. In detail, die sticking (abnormal wear) caused by excessive increase in the compression force between the upper die 110 and the metal plate 10 can be inhibited.

[0078] Figure 10 is a cross-sectional view showing a third modification of Figure 7

[0079] In the third modification, the elastic member 124 is chamfered not only at the end portion 124a protruding from the holding groove 122b but also at the end portion 124b inserted into the holding groove 122b in the illustrated cross section. The chamfering is, for example, a bevel chamfer having a chamfer angle of 45°.

[0080] Figure 11 is a cross-sectional view showing a fourth modification of Figure 7

[0081] ​​​​In the fourth modification, the elastic member 124 has a rounded shape not only at the end portion 124a protruding from the holding groove 122b but also at the end portion 124b inserted into the holding groove 122b in the illustrated cross section. The rounded shape is, for example, a semicircular shape in the illustrated cross section. That is, the elastic member 124 of the present modification is circular in the illustrated cross section.

[0082] According to the third and fourth modifications, a deformation allowance (deformation margin) of the elastic member 124 can be ensured in the holding groove 122b. Without the deformation allowance of the elastic member 124, very high pressure acts on the elastic member 124, and die sticking can occur. In detail, die sticking (abnormal wear) caused by excessive increase in the compression force between the upper die 110 and the metal plate 10 can be suppressed.

[0083] Figure 12 is a cross-sectional view illustrating a fifth modification of Figure 7 .

[0084] In the fifth modification, the elastic member 124 has a rounded shape not only at the end portion 124a protruding from the holding groove 122b but also at the end portion 124b inserted into the holding groove 122b in the illustrated cross section. The rounded shape is, for example, a chamfered angle with a chamfer angle of 45°. In addition, the elastic member 124 of the fifth modification has a hollow 124c in the inner center. The hollow 124c is circular in the illustrated cross section.

[0085] According to the fifth modification, the flexibility of the elastic member 124 can be increased, and die sticking caused by very high pressure acting on the elastic member 124 can be suppressed. In detail, die sticking (abnormal wear) caused by excessive increase in the compression force between the upper die 110 and the metal plate 10 can be suppressed.

[0086] Figure 13 is a cross-sectional view illustrating a sixth modification of Figure 7 .

[0087] In the sixth modification, the holding groove 122b has a shape in which the bottom portion 122b2 is wider than the opening portion 122bl in the illustrated cross section. In detail, the inner side surface 122b3 connecting the opening portion 122bl and the bottom portion 122b2 is tapered so as to narrow from the bottom portion 122b2 toward the opening portion 122bl. In addition, the elastic member 124 has an end portion 124a having the same shape as that of the fifth modification and an end portion 124b having a shape complementary to that of the holding groove 122b.

[0088] Figure 14 is a cross-sectional view illustrating a seventh modification of Figure 7 .

[0089] In the seventh modification, the holding groove 122b has a shape in which theFigure 13 Also, the bottom portion 122b2 has a shape in which the width of the opening portion 122b1 is wider than that of the bottom portion 122b2. In detail, the inner side surface 122b3 connecting the opening portion 122b1 and the bottom portion 122b2 becomes a stepped shape in a manner that narrows from the bottom portion 122b2 toward the opening portion 122b1. Further, the elastic member 124 has an end portion 124a having the same shape as that of the 5th modification example, and an end portion 124b having a shape complementary to the holding groove 122b.

[0090] According to the 6th and 7th modification examples, since the elastic member 124 (particularly, the end portion 124b) is caught in the holding groove 122b, it is possible to suppress the elastic member 124 from falling out of the holding groove 122b. In the present embodiment, the end portion 124b of the elastic member 124 has a shape complementary to the holding groove 122b, but is not limited thereto. At the time of press forming, the elastic member 124 is deformed in a manner that matches the shape of the holding groove 122b due to pressure, so it is possible to exert the fall-out suppression effect of the elastic member 124 regardless of the shape of the elastic member 124.

[0091] (2nd Embodiment)

[0092] Reference Figure 15 The device 50 and the method for manufacturing the metal resin composite 1 of the 2nd embodiment will be described. In the present embodiment, the shape of the metal resin composite 1 is different from that of the 1st embodiment. The structure related thereto is the same as that of the 1st embodiment of the metal resin composite 1 except for the following. Figures 1-6 Thus, there are cases where the description of the parts indicated in the 1st embodiment is omitted.

[0093] In the present embodiment, the metal resin composite 1 has a protrusion 2a in the bottom wall portion 2. The protrusion 2a is composed of the resin material 20 and extends elongatedly upward in the vertical direction. Further, in the 1st formed upper surface 111, a recess 111a having a shape complementary to the protrusion 2a is formed. The recess 111a is open downward in the 1st formed upper surface 111.

[0094] In the case where the resin material 20 is formed elongatedly like the protrusion 2a, sufficient filling pressure is required, but here since the filling pressure of the resin material 20 is increased by the elastic member 124, it is possible to stably form an elongated shape like the protrusion 2a.

[0095] From the above, the specific embodiments of the present application and the modification examples thereof have been described, but the present application is not limited to the above-described modes and can be variously modified within the scope of the present application. For example, a mode in which the contents of each of the embodiments and the modification examples are appropriately combined can also be employed as one embodiment of the present application.

[0096] Further, as the resin material 20, a material in which glass fibers or carbon fibers are impregnated in a thermoplastic resin can also be used. In this case, the resin material 20 is put into the mold 100 in a state in which it is heated and softened. Then, by cooling and solidifying it in the mold 100 on the metal plate 10, the metal resin composite 1 is manufactured.

[0097] Further, in the metal resin composite 1, an adhesive layer can also be provided between the metal plate 10 and the resin material 20. In this case, by providing the adhesive layer, the metal member 10 and the resin material 20 can be firmly integrally molded.

[0098] Further, with reference to Figure 16 The metal plate 10 can also be press-molded into a complete hat shape in the second process (first pressurization). In this case, an upper mold 110A having a molding surface of a complete hat shape is used to press-mold the metal plate 10 into a complete hat shape. Alternatively, the same upper mold can be used in the first pressurization and the second pressurization. Further, in the example of Figure 16 In the example of FIG. 12, the elastic member 124 is not installed in the holding groove 122b. This is because, since the resin material 20 is not disposed in the first pressurization, the elastic member 124 for suppressing the leakage of the resin material 20 is not needed to be installed. In addition, separate lower molds can be used in the first pressurization and the second pressurization, and the lower mold used in the first pressurization can also not have the holding groove 122b.

[0099] Explanation of Reference Numerals

[0100] 1 Metal resin composite

[0101] 2 Bottom wall portion

[0102] 3 Side wall portion

[0103] 4 Flange portion

[0104] 10 Metal plate (metal member)

[0105] 20 Resin material

[0106] 20a End surface

[0107] 50 Apparatus

[0108] 100 Mold

[0109] 110, 110A Upper mold

[0110] 111 First molding upper surface

[0111] 111a Concave portion

[0112] 112 Second molding upper surface

[0113] 112a step difference

[0114] 113 3rd formed upper surface

[0115] 120 lower mold

[0116] 121 1st formed lower surface

[0117] 122 2nd formed lower surface

[0118] 122b holding groove

[0119] 122b1 opening portion

[0120] 122b2 bottom portion

[0121] 122b3 inner side surface

[0122] 123 3rd formed lower surface

[0123] 124 elastic member

[0124] 124a, 124b end portion

[0125] 130 drive portion

[0126] 140 heating portion

[0127] C cavity

Claims

1. A method for manufacturing a metal-resin composite, comprising pressing a metal component and a resin material together to form the metal-resin composite, characterized in that... include: The lower mold, the aforementioned metal parts, the aforementioned resin material, and the upper mold are arranged sequentially. The aforementioned metal component and resin material are clamped together using the aforementioned upper mold and lower mold. By means of the aforementioned clamping, the aforementioned metal component is pushed against the aforementioned upper mold via the elastic member installed on the forming surface of the aforementioned lower mold, thereby sealing the cavity formed by the aforementioned upper mold and the aforementioned lower mold; While enclosing the aforementioned resin material in the aforementioned cavity, the aforementioned metal component and the aforementioned resin material are integrated by means of the aforementioned pressure molding.

2. The method for manufacturing a metal-resin composite as described in claim 1, characterized in that, The aforementioned metal-resin composite has, in a cross section perpendicular to the length direction, a bottom wall portion extending in the horizontal direction, a side wall portion erected from both ends of the aforementioned bottom wall portion, and a flange portion extending outward in the horizontal direction from the aforementioned side wall portion. In the aforementioned cross section, the aforementioned upper mold has a first forming upper surface for forming the aforementioned bottom wall portion, a second forming upper surface for forming the aforementioned side wall portion, and a third forming upper surface for forming the aforementioned flange portion; The aforementioned lower mold has, in the aforementioned cross section, a first forming lower surface for forming the aforementioned bottom wall portion, a second forming lower surface for forming the aforementioned side wall portion, and a third forming lower surface for forming the aforementioned flange portion.

3. The method for manufacturing a metal-resin composite as described in claim 2, characterized in that, A step difference is provided on the aforementioned second forming upper surface.

4. The method for manufacturing a metal-resin composite as described in claim 3, characterized in that, On the aforementioned second forming lower surface, a retaining groove is provided for retaining the aforementioned elastic member; The thickness of the aforementioned elastic component is greater than the depth of the aforementioned retaining groove.

5. The method for manufacturing a metal-resin composite as described in claim 4, characterized in that, The aforementioned retaining groove has a shape in the aforementioned cross-section where the bottom is wider than the opening.

6. The method for manufacturing a metal-resin composite as described in claim 4 or 5, characterized in that, The aforementioned retaining groove is positioned at the same height as or higher than the aforementioned step difference when the aforementioned upper mold and the aforementioned lower mold are closed.

7. The method for manufacturing a metal-resin composite as described in claim 4 or 5, characterized in that, In the aforementioned cross-section, the end of the aforementioned elastic member protruding from the aforementioned retaining groove is chamfered or has a rounded shape.

8. The method for manufacturing a metal-resin composite as described in claim 4 or 5, characterized in that, In the aforementioned cross-section, the end of the aforementioned elastic member inserted into the aforementioned retaining groove is chamfered or has a rounded shape.

9. The method for manufacturing a metal-resin composite as described in any one of claims 1 to 5, characterized in that, It also includes: before integrating the aforementioned metal component and the aforementioned resin material by means of the aforementioned pressure molding, only the aforementioned metal component is pressure molded into a hat shape.

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