Apparatus and method for manufacturing metal resin composite

Abstract

This invention provides an apparatus and method for manufacturing a metal-resin composite. The method integrates a resin part with a metal extrusion part by pressure molding, comprising: preparing a mold including a first mold and a second mold, the first mold forming a receiving portion for accommodating at least a portion of the extrusion part, the second mold being movable relative to the first mold in an opening and closing direction; accommodating the extrusion part in the receiving portion, and disposing the resin part on the first mold; and moving the second mold in a mold-closing direction to form a cavity defined by the surface of the extrusion part and the mold, and pressurizing the resin part to fill the cavity. The extrusion part has a protrusion that protrudes from the surface and approaches the receiving portion when the extrusion part is in the receiving state. During filling, the protrusion is brought into close contact with the receiving portion or its periphery by a forming pressure applied to the extrusion part from the mold, thus blocking the cavity from the gap between the inner surface of the receiving portion and the surface of the extrusion part.

Description

Technical Field

[0001] This invention relates to an apparatus and method for manufacturing metal-resin composites. Background Technology

[0002] Various construction and manufacturing methods have been proposed for metal-resin composites used in structural parts such as vehicle frames. For example, in the composite disclosed in Patent Document 1, a thermosetting carbon fiber reinforced resin (CFRP) is bonded to the surface of an aluminum extrusion using an adhesive. In the composite disclosed in Patent Document 2, the aluminum sheet and CFRP are integrated by hot-pressing CFRP onto an aluminum sheet.

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2017-119422 Patent Document 2: Japanese Patent Application Publication No. 2020-104411 Summary of the Invention

[0004] The problem that the invention aims to solve In the manufacture of a composite comprising an aluminum extrusion, when applying the hot pressing method illustrated in Patent Document 2, it is conceivable that a die needs to be prepared taking into account the tolerances of the aluminum extrusion to create a corresponding gap between the die and the aluminum extrusion, which is assumed to have a reference size. Thus, for each composite manufactured, the aluminum extrusion, formed within the tolerances, can be properly positioned in the die. On the other hand, the aluminum extrusion is hot-extruded as taught in Patent Document 1. Therefore, twisting and bending easily occur during extrusion, making it difficult to improve the dimensional accuracy of the aluminum extrusion.

[0005] It is conceivable that, in contrast to the lower dimensional accuracy of aluminum extrusions, the gap between the die and the aluminum extrusion needs to be much larger than the gap between the mating surfaces of the die. Consequently, during hot pressing, the resin component unintentionally flows into the gap between the die and the aluminum extrusion, thus reducing the production efficiency of the composite. For example, the demolding resistance increases because the resin component cures within the gap. After demolding, this results in the troublesome task of peeling off unwanted resin component that has cured within the gap. To avoid insufficient resin component on the aluminum extrusion, it is necessary to anticipate the amount of peeling and pre-fill with excess resin component.

[0006] The objective of this invention is to suppress the flow of resin into the gap between the mold and the extruder when manufacturing a metal-resin composite by pressing a resin part onto an extruder.

[0007] Methods used to solve problems A first aspect of the present invention provides a method for manufacturing a metal-resin composite, wherein a resin part is integrally formed with a metal extrusion by pressure molding; comprising: preparing a mold including a first mold and a second mold, the first mold forming a receiving portion for receiving at least a portion of the extrusion, the second mold being movable relative to the first mold in an opening and closing direction; receiving the extrusion in the receiving portion, and disposing the resin part on the first mold; and moving the second mold in a mold closing direction to form a cavity defined by the surface of the extrusion and the mold, and pressurizing the resin part to fill the cavity; the extrusion having a protrusion protruding from the surface and approaching the receiving portion when the extrusion is received in the receiving portion; during the filling, the protrusion is brought into close contact with the receiving portion or its periphery by forming pressure applied to the extrusion from the mold, thereby blocking the cavity from the gap between the inner surface of the receiving portion and the surface of the extrusion.

[0008] According to the above structure, by utilizing the forming pressure applied to the extruder during cavity formation, the protrusions provided on the extruder are brought into close contact with the mold, thereby blocking the gap between the surface of the extruder and the inner surface of the receiving portion from the cavity. Therefore, it is possible to prevent the resin part from unintentionally flowing from the cavity into the gap between the extruder and the mold.

[0009] Alternatively, in the aforementioned filling process, the aforementioned forming pressure is applied to the aforementioned extrusion via the aforementioned resin component.

[0010] According to the above structure, the chamber can be blocked from the gap by the pressure applied from the resin part to the extruder.

[0011] Alternatively, the aforementioned extrusion member has a pair of flanges that extend along the aforementioned inner surface of the aforementioned receiving portion in the aforementioned receiving state; the aforementioned protrusions are provided in pairs on each of the aforementioned pair of flanges; the aforementioned pair of flanges form an inner space between each other on their inner surfaces, the aforementioned inner space constituting part of the aforementioned chamber; during the aforementioned filling, the aforementioned forming pressure is applied to the aforementioned pair of flanges via the aforementioned resin member flowing into the aforementioned inner space, the aforementioned pair of flanges flex toward the aforementioned inner surface of the aforementioned receiving portion, and the aforementioned protrusions are in close contact with the aforementioned receiving portion or its periphery.

[0012] According to the above structure, by allowing the resin component to flow into a pair of flanges, a structure is achieved in which the pressure of the resin component deforms the extrusion component. By integrating the resin component filled into the inner space with the extrusion component, the contact area between the resin component and the extrusion component is increased, and the resin component is more firmly bonded to the extrusion component.

[0013] Alternatively, the aforementioned protrusion may be disposed on the outer surface of the aforementioned flange; during the filling of the aforementioned resin component, the aforementioned protrusion is in close contact with the aforementioned inner surface of the aforementioned receiving portion.

[0014] According to the above structure, the resin component applies pressure in the thickness direction of the flange. Since the protrusion is in close contact with the receiving portion along the direction of this pressure, gaps are easily eliminated.

[0015] Alternatively, the aforementioned extrusion member may have an inner inclined surface, which is disposed on at least one of the front ends of the aforementioned pair of flanges; the aforementioned inner inclined surface is inclined in the aforementioned receiving state in such a way that it moves away from the aforementioned receiving portion as it moves toward the base end side of the aforementioned pair of flanges.

[0016] According to the above structure, when the resin part flows into the inner space, if the inner inclined surface is acted upon in the mold closing direction, the wedge action will push the inner inclined surface towards the receiving part. As a result, the flange can more easily bend towards the receiving part, making it easier to fill the gap.

[0017] Alternatively, the aforementioned extrusion member may have a protrusion disposed at at least one of the front ends of the aforementioned pair of flanges, protruding toward the aforementioned inner space side beyond the inner surface of the flange; the aforementioned inner inclined surface is formed on the aforementioned protrusion.

[0018] According to the above structure, the resin part is closed by the protrusion, and the bonding strength between the resin part and the extrusion part is improved.

[0019] Alternatively, the aforementioned extruder may have a pair of outer inclined surfaces disposed on the lower surface side of at least one of the aforementioned pair of protrusions, and in the aforementioned receiving state, it is inclined away from the aforementioned receiving part in the receiving direction toward receiving the aforementioned extruder; in the aforementioned receiving of the aforementioned extruder, the aforementioned flange flexes toward the aforementioned inner space side due to the interference between the aforementioned outer inclined surfaces and the aforementioned receiving part, and the aforementioned protrusion is in close contact with the aforementioned inner surface of the aforementioned receiving part due to the elastic force of the aforementioned flange.

[0020] According to the above structure, the flange can be flexed inward by the wedge action of the outer inclined surface while the extruded part is received. The reaction force generated by the elastic deformation of the flange can also be used to make the protrusion and the receiving part fit tightly, and the gap can be filled more reliably.

[0021] Alternatively, the aforementioned extrusion member may have a protruding piece that protrudes outward from at least one of the front ends of the aforementioned pair of flanges and is exposed from the aforementioned receiving portion in the aforementioned receiving state; the aforementioned protrusion is provided at the front end of the aforementioned protruding piece; during the filling of the aforementioned resin member, the aforementioned protrusion is in close contact with the periphery of the aforementioned receiving portion.

[0022] According to the above structure, since the gap is filled outside the receiving part, the unwanted inflow of resin parts can be reduced.

[0023] Alternatively, the aforementioned protruding piece may have a pressure-bearing surface that is perpendicular to the opening and closing direction of the aforementioned mold in the aforementioned receiving state; the aforementioned protrusion is provided at the front end of the aforementioned protruding piece and is opposite to the aforementioned peripheral portion in the aforementioned opening and closing direction.

[0024] According to the above structure, the protruding piece is pressed against the periphery of the receiving part not only by the deflection of the flange but also by the forming pressure acting on itself. Therefore, the tightness of the protrusion is improved, and the gap can be filled more reliably.

[0025] Alternatively, the aforementioned mold may also include a third mold, which is movable relative to the aforementioned first mold in the opening and closing direction of the aforementioned mold, and together with the aforementioned first mold forms the aforementioned receiving portion; the aforementioned protrusion protrudes in the aforementioned opening and closing direction in the aforementioned receiving state, the aforementioned third mold contacts the aforementioned protrusion, and the aforementioned forming pressure is applied to the aforementioned extruded part from the aforementioned third mold.

[0026] According to the above structure, since the third mold, which can move in the opening and closing direction, also forms a receiving part, even if the cross-sectional shape of the extruded part is complex, it is easy to place the extruded part onto the mold and demold it. In this case, the forming pressure of the third mold acts directly on the protrusion. As a result, surface pressure is generated locally on the protrusion, making the protrusion and the receiving part come into close contact. Therefore, it is easy to fill the gap.

[0027] Alternatively, the aforementioned protrusions may be arranged in pairs on both sides of the aforementioned opening and closing direction of the aforementioned extrusion member, with one of the aforementioned protrusions blocking the portion formed by the aforementioned extrusion member and the aforementioned first mold in the aforementioned gap from the aforementioned chamber, and the other of the aforementioned protrusions blocking the portion formed by the aforementioned extrusion member and the aforementioned third mold in the aforementioned gap from the aforementioned chamber.

[0028] According to the above structure, the forming pressure from the third mold can fill both the gap of the first mold and the gap of the second mold.

[0029] Alternatively, the protrusion of the aforementioned one may protrude toward the surface of the aforementioned extrusion member that is disposed on the aforementioned first mold, in a direction close to the aforementioned first mold.

[0030] According to the above structure, the forming pressure from the third mold can be used to make one of the protrusions come into close contact with the first mold, which can more reliably fill the gap.

[0031] Alternatively, the protrusion of the other party may be provided in the stepped portion of the extrusion to form a hook shape, and the third mold may contact the protrusion of the other party, and the third mold may apply the forming pressure to the protrusion of the other party.

[0032] According to the above structure, the hook-shaped stepped portion can be flexed by the forming pressure from the third mold, so that the protrusion on the other side can be brought into close contact with the third mold. Therefore, the gap can be filled more reliably.

[0033] A second aspect of the present invention provides an apparatus for manufacturing a metal-resin composite, which integrates a resin part with a metal extrusion by pressure molding; comprising: a mold including a first mold and a second mold, the first mold forming a receiving portion for at least partially receiving the extrusion, the second mold being movable relative to the first mold; and a moving mechanism for moving the second mold; the extrusion having a protrusion protruding from the surface of the extrusion and approaching the receiving portion when the extrusion is received in the receiving portion; if the second mold is moved by the moving mechanism while the resin part is disposed on the first mold, a cavity is formed by the surface of the extrusion and the mold, the resin part is pressurized and filled into the cavity, and the protrusion comes into close contact with the receiving portion or its periphery by the forming pressure applied to the extrusion from the mold, the cavity being blocked by the gap between the inner surface of the receiving portion and the surface of the extrusion.

[0034] Invention Effects According to the present invention, when manufacturing a metal-resin composite by pressurizing a resin part onto an extruder, it is possible to suppress the flow of the resin part into the gap between the mold and the extruder. Attached Figure Description

[0035] Figure 1A This is a top view of a metal-resin composite manufactured by the manufacturing apparatus and method according to the first embodiment of the present invention.

[0036] Figure 1B yes Figure 1A The B-B sectional view.

[0037] Figure 2A This is a cross-sectional view of the manufacturing apparatus according to the first embodiment.

[0038] Figure 2B yes Figure 2A The B-B sectional view.

[0039] Figure 3 This is a conceptual diagram of the manufacturing method according to the first embodiment.

[0040] Figure 4 This is a cross-sectional view of an extruded part prepared during the manufacture of the metal-resin composite according to the first embodiment.

[0041] Figure 5 This is a conceptual diagram of the manufacturing method according to the first embodiment.

[0042] Figure 6 This is a conceptual diagram of the manufacturing method according to the first embodiment.

[0043] Figure 7 yes Figure 6 A magnified view of a portion of the image.

[0044] Figure 8 It is equivalent to the second embodiment. Figure 4 The image.

[0045] Figure 9 It is equivalent to the second embodiment. Figure 3 The image.

[0046] Figure 10 It is equivalent to the second embodiment. Figure 7 The image.

[0047] Figure 11 This is a cross-sectional view of a metal-resin composite manufactured by the manufacturing apparatus and method according to the third embodiment.

[0048] Figure 12 It is equivalent to the third embodiment. Figure 3 The image.

[0049] Figure 13 It is equivalent to the third embodiment. Figure 6 The image.

[0050] Figure 14 It is equivalent to the third embodiment. Figure 7 The image.

[0051] Figure 15A This is a top view of a metal-resin composite manufactured by the manufacturing apparatus and method according to the fourth embodiment.

[0052] Figure 15B yes Figure 15A The B-B sectional view.

[0053] Figure 16 This is a cross-sectional view of an extruded part prepared during the manufacture of the metal-resin composite according to the fourth embodiment.

[0054] Figure 17 This is a conceptual diagram of the manufacturing apparatus and manufacturing method according to the fourth embodiment.

[0055] Figure 18 This is a conceptual diagram of the manufacturing method involved in the fourth embodiment.

[0056] Figure 19 This is a conceptual diagram of the manufacturing method involved in the fourth embodiment.

[0057] Figure 20 This is a conceptual diagram of the manufacturing method involved in the fourth embodiment.

[0058] Figure 21 This is a conceptual diagram of the manufacturing method involved in the fourth embodiment.

[0059] Figure 22 It is equivalent to the fifth embodiment. Figure 15B The image.

[0060] Figure 23 It is equivalent to the fifth embodiment. Figure 16 The image.

[0061] Figure 24 It is equivalent to the fifth embodiment. Figure 17 The image.

[0062] Figure 25 It is equivalent to the fifth embodiment. Figure 18 The image.

[0063] Figure 26 It is equivalent to the fifth embodiment. Figure 19 The image.

[0064] Figure 27 It is equivalent to the fifth embodiment. Figure 20 The image.

[0065] Figure 28 It is equivalent to the fifth embodiment. Figure 21 The image.

[0066] Figure 29 It is equivalent to the fifth embodiment. Figure 15B The image.

[0067] Figure 30 It is equivalent to the fifth embodiment. Figure 16 The image.

[0068] Figure 31 It is equivalent to the fifth embodiment. Figure 17 The image.

[0069] Figure 32 It is equivalent to the fifth embodiment. Figure 18 The image.

[0070] Figure 33 It is equivalent to the fifth embodiment. Figure 19 The image.

[0071] Figure 34 It is equivalent to the fifth embodiment. Figure 20 The image.

[0072] Figure 35 It is equivalent to the fifth embodiment. Figure 21 The image. Detailed Implementation

[0073] Embodiments of the present invention will be described with reference to the accompanying drawings. The same or corresponding elements are given the same reference numerals throughout the drawings, and repeated descriptions are omitted.

[0074] In the manufacturing apparatus 1 and manufacturing method of the metal-resin composite 100, the resin part 300 and the metal extrusion part 200 are integrally formed by pressing the mold 2 (see reference). Figure 1A and Figure 2A The X direction in the diagram corresponds to the extrusion direction or length direction of the extruder 200. When simply referred to as a "section," it refers to a section orthogonal to the X direction. The Y direction is a direction within the section, corresponding to the width direction of the extruder 200. The Z direction is orthogonal to the Y direction within the section, corresponding to the height direction of the extruder 200, and also to the opening and closing direction of the mold 2. Since the Z direction is oriented vertically towards the paper in several diagrams, for ease of explanation, the Z direction will be considered vertical, and the XY direction horizontal. The upper direction (+Z direction) corresponds to the mold opening direction M1, and the lower direction (-Z direction) corresponds to the mold closing direction M2. However, this is just one example; the orientation of the metal-resin composite 100 and its constituent elements, as well as the manufacturing apparatus 1 and its constituent elements, can be appropriately changed.

[0075] (First Embodiment) Reference Figure 1A and Figure 1B The metal-resin composite 100 according to the first embodiment includes a metal extrusion 200 and a resin part 300 disposed on the extrusion 200. The metal-resin composite 100 is preferably applied to structural parts such as the body frame of an automobile.

[0076] There are no particular restrictions on the metal raw materials for extruded part 200. Light alloys such as aluminum alloys and magnesium alloys are preferred examples of metal raw materials, which help to balance the lightweight and high rigidity of the structural parts. Hereinafter, extruded part 200 is made of aluminum alloy, just as an example.

[0077] Detailed illustrations are omitted, but the extruded part 200 is obtained by heating and compressing a billet-shaped metal raw material within the body of an extruder, and then extruding it from a die mounted on the body. After extrusion from the die, necessary processes such as cooling, drawing, and cutting are performed. The cross-section of the extruded part 200 is uniform in the longitudinal direction X because it is determined by the shape of the die. However, it undergoes twisting and bending due to thermoforming. All elements of the extruded part 200 extend in the longitudinal direction X and are integrally formed without seams.

[0078] Resin part 300 is manufactured in manufacturing apparatus 1 (see reference 1) Figure 2A and Figure 2B The compound is obtained by pressing and molding the compound. The compound can be either a sheet-shaped SMC (Sheet Molding Compound) or a block-shaped BMC (Bulk Molding Compound). SMC or BMC is achieved by impregnating fibers with a matrix resin using fiber-reinforced plastic (FRP). The matrix resin contains a thermosetting resin such as an unsaturated polyester as the main component, with additives mixed into the main component. Additives include, for example, a release agent. The fibers, such as glass fibers or carbon fibers, are cut relatively short and oriented in a random direction within the compound. However, the resin part 300 is not limited to a thermosetting resin and can also be a thermoplastic resin. Hereinafter, as an example only, the resin part 300 is made of SMC.

[0079] In this embodiment, the extruder 200 has a rectangular cross-section. The longer side of the rectangle extends in the height direction Z, and the shorter side extends in the width direction Y. The resin part 300 is disposed on the upper part of the extruder 200 and is formed into a plate shape with a width larger than that of the extruder 200. The cross-section of the metal-resin composite 100 is formed into a T-shape and is linearly symmetrical about the center line in the width direction. The cross-sections of the extruder 200 and the resin part 300 are also linearly symmetrical.

[0080] Furthermore, the top view shape of the resin part 300 is not particularly limited. Here, as just one example, the top view shape is a rectangle with the long side extending in the length direction X and the short side extending in the width direction Y. The short side of the resin part 300 matches the two ends of the extruded part 200 in the length direction X, and the cross section of the metal-resin composite 100 is the same in the length direction X.

[0081] Reference Figure 2A and Figure 2B The manufacturing apparatus 1 mainly includes a mold 2, a drive unit 3, and a heating unit 4. The mold 2 includes a first mold 10 and a second mold 20. The first mold 10 is configured as a fixed mold, a lower mold, or a die. The second mold 20 is configured as a movable mold, an upper mold, or a punch. The second mold 20 is positioned above the first mold 10 (i.e., in the mold opening direction M1) and is movable relative to the first mold 10 in the vertical direction (i.e., in the opening and closing direction).

[0082] The first mold 10 has a base 11 and a shoulder 12. The upper surface of the base 11 forms a horizontal lower forming surface 41. The shoulder 12 protrudes upward from the periphery of the base 11, and the inner surface of the shoulder 12 extends upward from the lower forming surface 41. The inner surface of the shoulder 12 is identical to the top view shape of the resin part 300 of the metal-resin composite 100 in a cross section perpendicular to the opening and closing direction (detailed illustration omitted). In this example, since the top view shape of the resin part 300 is rectangular (see reference...), Figure 1A ), so if from Figure 2A and Figure 2B As can be seen, the shoulder 12 is rectangular window frame-shaped when viewed from above. The lower part of the inner surface of the shoulder 12 forms a vertical side forming surface 42. The upper part of the inner surface of the shoulder 12 forms a lower mating surface 14.

[0083] The first mold 10 has a receiving portion 15 for accommodating the extruded part 200. The receiving portion 15 is recessed in the lower forming surface 41. The receiving portion 15 has a U-shaped inner surface 16, which is configured as a groove open in the lower forming surface 41. The inner surface 16 of the receiving portion 15 includes a pair of inner side surfaces 16a and 16b that are continuous with the lower forming surface 41 and extend downward, and an inner bottom surface 16c that horizontally connects the inner side surfaces 16a and 16b to each other.

[0084] The second mold 20 has a main body 21. The main body 21 is, for example, cuboid in shape. The lower surface of the main body 21 forms an upper forming surface 43 that opposes the lower forming surface 41 in the opening / closing direction. The side surface of the main body 21 forms an upper mating surface 24 extending upward from the periphery of the lower forming surface 41. The upper mating surface 24, in a cross-section perpendicular to the opening / closing direction (detailed illustration omitted), is similar to, but slightly smaller than, the cross-section of the inner surface of the shoulder 12. For convenience, this interval is exaggerated in the figures.

[0085] The drive unit 3 moves the second mold 20 in the opening and closing direction between the retracted position (refer to the solid line) and the bottom dead center (refer to the double-dotted line). The heating unit 4 heats the mold 2.

[0086] Hereinafter, the metal-resin composite 100 (refer to) manufactured using the manufacturing apparatus 1 described above will be described. Figure 1A The method is explained. At the same time, the structure of mold 2, extrusion part 200, resin part 300 and metal-resin composite 100 is further explained.

[0087] Reference Figure 3The mold 2 is constructed as described above and below, and prepared in the manufacturing apparatus 1. Furthermore, for each metal-resin composite 100 manufactured, a composite of the extrusion part 200 and the resin part 300 is prepared. The second mold 20 is positioned in the retracted position. With the second mold 20 in the retracted position, the extrusion part 200, the composite, and the metal-resin composite 100 can be easily set up, so the upper forming surface 43 is sufficiently far upward relative to the upper end surface of the first mold 10.

[0088] Reference Figure 4 The prepared extrusion member 200 has a bottom wall 201, a pair of side walls 202 and 203, and a top wall 204. The pair of side walls 202 and 203 form the long sides of a rectangular cross-section, extending in the height direction Z, while the bottom wall 201 and the top wall 204 form the short sides of a rectangular cross-section, extending in the width direction Y. The pair of side walls 202 and 203 are erected upwards from a pair of side edges of the bottom wall 201. The top wall 204 connects the upper parts of the side walls 202 and 203 to each other.

[0089] The extrusion member 200 has a hollow 210 defined by the inner surfaces of walls 201-204 and one or more partition walls 205 dividing the hollow 210. The hollow 210 is open at both ends in the longitudinal direction X. In this embodiment, the partition wall 205 is single, and in the vertical direction Z, the inner surfaces of the side walls 202 and 203 are connected to each other between the bottom wall 201 and the upper wall 204, and the hollow 210 is divided into a first chamber 211 and a second chamber 212 by the partition wall 205 in the vertical direction Z. However, multiple partition walls may be arranged at intervals in the vertical direction Z, or the partition walls may be omitted.

[0090] The extrusion 200 has a pair of flanges 222 and 223. The pair of flanges 222 and 223 are portions extending upward from a pair of sidewalls 202 and 203. The outer surface of flange 222 is substantially flush with the outer surface of sidewall 202, and together with the outer surface of sidewall 202, forms the overall outer surface of the extrusion 200. The thickness of flange 222 is the same as, or thinner than, the thickness of sidewall 202. The relationship between flange 223 and sidewall 203 is similar.

[0091] The extrusion 200 has an inner space 220 defined by the outer surface (i.e., upper surface) of the upper wall 204 and the inner surfaces of a pair of flanges 222, 223. The inner space 220 is open in both directions of the length direction X and above. The front ends (i.e., upper ends) of the pair of flanges 222, 223 in the height direction Z form an opening 221 of the inner space 220.

[0092] The extrusion member 200 has a pair of protrusions 224 and 225, which are respectively disposed at the front ends of a pair of flanges 222 and 223. Each protrusion 224 and 225 protrudes inward in the width direction Y from the front end of the corresponding flange 222 and 223. In other words, the protrusions 224 and 225 protrude toward the inner space 220 in a manner close to each other. As a result, the upper opening 221 is narrowed compared to the case without the protrusions 224 and 225. Furthermore, the lower surfaces of the protrusions 224 and 225 face the inner space 220.

[0093] The extrusion member 200 has inner inclined surfaces 226 and 227, which are disposed at the front ends of a pair of flanges 222 and 223 (specifically, in this embodiment, a pair of protrusions 224 and 225). The inner inclined surfaces 226 and 227 connect the upper surface of the protrusions 224 and 225 to the side surface, and are inclined inward in the width direction Y as they face downward. Viewed from the protrusions 224 and 225, the lower side corresponds to the base end side of the flanges 222 and 223, and also corresponds to the mold closing direction M2. The inner side corresponds to the inner space 220 side, and also corresponds to the side away from the receiving part 15.

[0094] The extrusion member 200 has protrusions 231, 232 protruding from its surface. In this embodiment, the protrusions 231, 232 are paired in the width direction Y. A pair of protrusions 231, 232 are respectively provided on the outer surface of a pair of flanges 222, 223, protruding outward from the pair of flanges 222, 223 in the width direction Y.

[0095] In particular, in this embodiment, a pair of protrusions 231 and 232 are respectively provided at the front ends of a pair of flanges 222 and 223. The protrusions 231 and convex portions 224 are integrated at the front end of the flange 222, protruding to both sides in the width direction Y from the front end, forming a common upper surface whose width is greater than the thickness of the flange 222. The relationship between the protrusions 232, convex portions 225 and flanges 223 is also the same.

[0096] Next, refer to Figure 3 and Figure 4 The prepared extrusion part 200 is housed in the receiving section 15. Then, the composite of the prepared resin part 300 is placed on the first mold 10. The extrusion part 200 and the composite can also be set manually. The manufacturing apparatus 1 may also be equipped with a manipulator for setting the extrusion part 200 and the composite.

[0097] The width of the receiving portion 15 is defined as the distance between the inner surfaces 16a and 16b in the width direction Y. The depth of the receiving portion 15 is defined as the length in the opening and closing direction from the lower forming surface 41 to the inner bottom surface 16c. The width of the extrusion 200 is defined as the distance between the side end faces of the protrusions 231 and 232 in the width direction Y. The height of the extrusion 200 is defined as the length in the height direction Z from the lower surface of the bottom wall 201 to the upper surface of the flanges 221 and 222 (i.e., the common upper surface of the protrusions 231 and 232 and the convex portions 224 and 225). The difference between the maximum allowable size and the minimum allowable size is defined as the dimensional tolerance. The dimensional tolerance of the extrusion 200 is set, for example, in the range of 0.5 to 1.0 mm. In addition to dimensional tolerances, the extrusion 200 may also be formed taking into account geometric tolerances, such as the flatness of the lower surface of the bottom wall 201 and the outer surfaces of the side walls 202 and 203. The prepared extrusion 200 is formed within tolerance.

[0098] In the housing of the extrusion 200, the extrusion 200 is inserted into the housing portion 15 in an insertion posture with its bottom wall 201 facing downward. The width of the housing portion 15 is the same as the maximum permissible dimension of the width of the extrusion 200. Therefore, the extrusion 200, formed within the dimensional tolerance, can move downward within the housing portion 15 without interfering with it.

[0099] The extrusion 200 is easily inserted into the inner bottom surface 16c because it does not interfere with the receiving portion 15 and is supported by its own weight. The depth of the receiving portion 15 is greater than the maximum permissible dimension of the height of the extrusion 200. Therefore, in the receiving state, the entire extrusion 200 is received in the receiving portion 15, and the upper surface of the extrusion 200 is located slightly below the lower forming surface 41. The sides of the protrusions 231 and 232 are separated by a small clearance and are opposite to the upper ends of the inner side surfaces of the receiving portion 15. Below the protrusions 231 and 232, a gap 51 is formed between the inner surface 16 of the receiving portion 15 and the surface of the extrusion 200 (e.g., the outer surfaces of the side walls 202 and 203, the lower surface of the bottom wall 201, etc.).

[0100] Reference Figure 3 Next, the mold 2 is preheated with the heating part 4 to raise the temperature of the mold 2 to the specified temperature. Then, the composite of the resin part 300 (e.g., SMC) is placed on the lower forming surface 41, and the extrusion part 200 housed in the housing part 15 is covered from above.

[0101] Next, refer to Figure 5The drive unit 3 moves the second mold 20 from its retracted position downwards to the mold closing direction M2 (downwards). During the downward movement of the second mold 20, the main body 21 is embedded in the shoulder 12, and the upper mating surface 24 is separated from the mold gap 52 by a slight gap and faces the lower mating surface 14. The second mold 20 is guided downwards by the shoulder 12. The second mold 20 pushes the composite of the resin part 300 downwards. The composite is softened by the heat of the mold 2 and flows under the molding pressure applied from the second mold 20.

[0102] Reference Figure 6 When the second mold 20 is positioned at the bottom dead center, the upper forming surface 43 and the lower forming surface 41 are separated in the opening and closing direction. The lower mating surface 14 is the portion of the inner surface of the shoulder 12 that is above the upper forming surface 43 when the second mold 20 is at the bottom dead center. The side forming surface 42 is the portion of the inner surface of the shoulder 12 that is below the upper forming surface 43 when the second mold 20 is at the bottom dead center. The lower forming surface 41, the side forming surface 42, and the upper forming surface 43 define the cavity 40 intended to fill the composite.

[0103] The chamber 40 communicates with the interior of the receiving portion 15 formed on the lower molding surface 41, and communicates with the inner space 220 via the upper opening 221 of the extruder 200 within the receiving portion 15. The inner space 220 is intended to be used as a filling object for the resin part 300. In other words, the inner space 220 constitutes part of the chamber 40, which is also defined by the surface of the extruder 200. The chamber 40 communicates with the mold gap 52. Similar to the mold gap 52, the gap 51 is not intended to be used as a filling object for the resin part 300.

[0104] In this regard, we also refer to Figure 7 During the downward movement of the second mold 20, the resin part 300 flows into the receiving portion 15 under downward pressure (refer to arrow 1). After the resin part 300 reaches the same level as the upper surface of the extruder 200 in the opening and closing direction, it is conceivable that the gap between the upper opening 221 and the protrusions 231, 232 and the inner surface 16 of the receiving portion 15 becomes the flow path of the resin part 300. However, since this gap has a very high inflow resistance compared to the upper opening 221, the resin part 300 must pass through the upper opening 221.

[0105] At this time, the resin part 300, based on the molding pressure applied from the second mold 20 (refer to arrow 1), exerts downward pressure (refer to arrow 2) on the inner inclined surfaces 226 and 227. As a result, the protrusions 224 and 225 are pushed outward in the width direction Y by the action of a wedge, and the flanges 222 and 223 flex outward in the width direction Y (refer to arrow 3). Furthermore, the resin part 300 flowing into the inner space 220, based on the molding pressure applied from the second mold 20, pushes against the surface defining the inner space 220 (refer to arrow 4), thereby causing the flanges 222 and 223 to flex outward in the width direction Y (refer to arrow 3). However, the inner inclined surfaces 226 and 227 can be omitted, and the end faces of the protrusions 224 and 225 can be connected perpendicularly to the upper surface. In this case, the molding pressure can also act perpendicularly on the inner surface of the ends, promoting the flexural deformation of the flanges 222 and 223 in the direction of arrow 3.

[0106] Thus, protrusions 231 and 232 are in close contact with the inner surfaces 16a and 16b of the receiving portion 15, respectively (refer to arrow 3). The deformation directions of flanges 222 and 223 are along the normal directions of the inner surfaces 16a and 16b. Therefore, by utilizing the deflection of flanges 222 and 223, protrusions 231 and 232 can easily be brought into close contact with the inner surfaces 16a and 16b.

[0107] In this way, the gap 51 can be filled by the action of a wedge before the resin part 300 flows into the gap 51. Thus, the cavity 40 is blocked from the gap 51, preventing the unintentional flow of the resin part 300 into the gap 51. Additionally, the mold gap 52 (see...) Figure 6 The gap is relatively narrow, resulting in higher flow resistance. Therefore, even if resin part 300 flows into the mold gap 52, the amount is relatively small before it ends.

[0108] Detailed illustrations are omitted, but if the second mold 20 is positioned at the bottom dead center for a predetermined period of time, the resin part 300 will cure. After the resin part 300 has cured, the drive unit 3 moves the second mold 20 to a retracted position in the mold opening direction M1 (upward). Then, the metal-resin composite 100 is removed from the first mold 10.

[0109] Because the inflow of resin part 300 into gap 51 is suppressed, the production efficiency of metal-resin composite 100 is increased. That is, since less resin part 300 is cured in receiving portion 15, demolding resistance can be suppressed to a lower level. After demolding, the operation of peeling unwanted resin part 300 from the surface of extrusion part 200 can also be simplified, and it can be completed by removing only the minimum required burrs. Since leakage of the composite is suppressed, it is easy to ensure an appropriate amount of resin part 300 in chamber 40, and the yield and quality rate are improved.

[0110] Back Figure 1A and Figure 1B The cured resin part 300 has a plate portion 301 protruding from the extruder 200 to both sides in the width direction Y, and a protrusion portion 302 protruding downward from the center of the plate portion 301 in the width direction Y. Upper forming surface 43, side forming surface 42, and lower forming surface 41 (see reference) Figure 6 The outline of the plate is transferred to the upper surface, side surface and lower surface of the plate 301 respectively.

[0111] The protrusion 302 is positioned in appearance to contribute to the gap 51 (see reference). Figure 6 The protrusions 231 and 232 are filled. The protrusion 302 is filled in the inner space 220 and contacts the lower surface of the protrusions 224 and 225. Since the resin part 300 is joined to the extrusion part 200, the bonding strength of the resin part 300 with respect to the extrusion part 200 is improved.

[0112] The area between the pair of flanges 222 and 223 is solidified by the resin part 300, thus possessing high strength. Therefore, it allows for thinner flanges 222 and 223, increasing flexibility. This also allows for easy adjustment of the gap 51 (see reference). Figure 7 ) to fill and ensure the strength of the metal-resin composite 100.

[0113] Furthermore, through the integration of protrusions 223, 224 and projections 231, 232, the width of the upper surface of flanges 222, 223 is increased compared to the thickness of flanges 222, 223. This ensures that the contact area between the extruded part 200 and the resin part 300 is maximized. Therefore, not only can the gap 51 (refer to...) be minimized at the upper end of the receiving portion 15... Figure 7 This reduces the amount of unnecessary resin parts 300 by filling in the gaps, and also maintains a high bonding strength between the resin parts 300 and the extrusion 200.

[0114] (Second Implementation) Hereinafter, the second embodiment will be described, focusing on the differences from the above-described embodiment.

[0115] Reference Figure 8 The extrusion member 200 also has outer inclined surfaces 233 and 234, which are disposed on the lower surface side of the protrusions 231 and 232. The outer inclined surfaces 233 and 234 connect the side surface of the protrusions 231 and 232 to the lower surface of the protrusions 231 and 232, and are inclined downwards towards the inside in the width direction Y.

[0116] The relationship between the depth of the receiving portion 15 and the height of the extrusion 200 is the same as in the first embodiment. The width of the receiving portion 15 is smaller than the maximum permissible dimension of the width of the extrusion 200. That is, the receiving portion 15 and the extrusion 200 formed within dimensional tolerances may interfere with each other in design.

[0117] The width of the receiving portion 15 may also be smaller than the minimum permissible dimension of the width of the extruded part 200. In this case, both the receiving portion 15 and the extruded part 200 formed within dimensional tolerances will interfere with each other by design. The width of the receiving portion 15 may also be set between the maximum and minimum permissible dimensions of the width of the extruded part 200, for example, it may be equal to the reference dimension of the width. When the width of the extruded part 200 is smaller than the reference dimension, the extruded part 200 is inserted into the receiving portion 15 without interfering with it, as in the first embodiment.

[0118] Reference Figure 9 When the width of the extrusion part 200 is larger than the width of the receiving portion 15, when the extrusion part 200 is received in the receiving portion 15 from above in an insertion position, the extrusion part 200 is inserted into the receiving portion 15 without interfering with it. Just before insertion is complete, the outer inclined surface 233 abuts against the corner of the inner side surface 16a and the lower forming surface 41 of the receiving portion 15, and the outer inclined surface 234 abuts against the corner of the inner side surface 16b and the lower forming surface 41 of the receiving portion 15. If a downward force is further applied to the extrusion part 200, the protrusions 231 and 232 move inward in the width direction Y by the action of a wedge, and the flanges 222 and 223 flex and deform inward in the width direction Y. Thus, the extrusion part 200 can move downward relative to the first mold 10. The extrusion part 200 moves downward until the bottom wall 201 sits on the inner bottom surface 16c of the receiving portion 15.

[0119] Reference Figure 10 The deformation of flanges 222 and 223 stops within the elastic range. If flanges 222 and 223 want to return to their original shape, they exert a reaction force from the elastic deformation in the outward direction of width Y (the side close to the inner surface of the receiving part 15) (see arrow 5). The sides of protrusions 231 and 232 are pressed against the inner surfaces 16a and 16b of the receiving part 15 by this reaction force, and are in close contact with the inner surfaces 16a and 16b (see arrow 3).

[0120] Then, with Figure 5 and Figure 6Similar to the first embodiment shown, the composite of the resin part 300 is disposed in the first mold 10 and pressurized under high temperature and high pressure. In this embodiment, the gap 51 is already filled in the stage before the resin part 300 is pressurized and molded. Therefore, the inflow of the resin part 300 into the gap 51 can be more reliably suppressed. Furthermore, similar to the first embodiment, based on the molding pressure applied from the resin part 300 to the inner inclined surfaces 226, 227 and the inner surfaces of the flanges 222, 223, the flanges 222, 223 are pushed outward in the width direction Y (see reference). Figure 10 (Arrows 1-4). Therefore, the sealing performance of chamber 40 is further improved.

[0121] Since the protrusions 231 and 232 are in close contact with the inner surface 16 of the receiving portion 15 by the reaction force generated by the elastic deformation of the flanges 222 and 223, although there is a possibility that the demolding resistance is slightly higher compared with the first embodiment, the curing of the resin part 300 in the gap 51 can be more reliably suppressed. Therefore, the production efficiency of the metal-resin composite 100 is higher, similar to the first embodiment.

[0122] (Third implementation) Hereinafter, the third embodiment will be described, focusing on the differences from the embodiments described above.

[0123] Reference Figure 11 The extrusion member 200 has outer inclined surfaces 233 and 234, which protrude outward in the width direction Y from the front ends of a pair of flanges 222 and 223, respectively. A pair of protruding pieces 235 and 236 are formed as flat plates extending vertically from the flanges 222 and 223. A pair of protrusions 231 and 232 are provided at the front ends of the pair of protruding pieces 235 and 236, respectively. Each protrusion 231 and 232 protrudes downward from the corresponding protruding piece 235 and 236. Thus, the protrusions 231 and 232 are provided on the outer surface of the flanges 222 and 223 via the protruding pieces 235 and 236.

[0124] Each protruding piece 235, 236 is integrated with the protrusion 224, 225 at the front end of the corresponding flange 222, 223, forming a common upper surface. Furthermore, in this embodiment, it is illustrated that the protrusions 224, 225 do not have inner inclined surfaces 226, 227 (see reference). Figure 4 However, the protrusions 224 and 225 can also have inner inclined surfaces 226 and 227, just like in the first embodiment.

[0125] Reference Figure 12The width of the receiving portion 15 is larger than the maximum permissible distance between the outer surfaces of the sidewalls 202 and 203. The depth of the receiving portion 15 is smaller than the minimum permissible length from the lower surface of the bottom wall 201 to the lower surface of the protrusions 235 and 236, and further smaller than the minimum permissible length from the lower surface of the bottom wall 201 to the lower surface of the protrusions. Thus, the extruder 200, as in the first embodiment, is inserted downward into the receiving portion 15 without interfering with it, until the bottom wall 201 is seated on the inner bottom surface 16c of the receiving portion 15.

[0126] In the housed state of the extrusion 200, the upper part of the extrusion 200 protrudes upward relative to the housing portion 15 or the lower forming surface 41. In particular, in this embodiment, based on the above-described dimensional relationship, not only the protruding pieces 235 and 236, but also the protrusions 231 and 232 do not interfere with the lower forming surface 41. The protruding pieces 235 and 236 extend in the width direction Y above the lower forming surface 41, and the lower surfaces of the protrusions 231 and 232 are positioned opposite the lower forming surface 41 with a slight clearance in the opening and closing direction. The composite of the resin part 300 can also be placed on the protruding pieces 235 and 236.

[0127] Reference Figure 13 and Figure 14 If the second mold 20 moves downward, the molding pressure acts downward through the resin part 300 on the upper surfaces 235a and 236a of the protrusions 235 and 236 (refer to arrow 6). The upper surfaces 235a and 236a function as pressure-bearing surfaces that withstand the molding pressure. The protrusions 235 and 236 flex downward, and the protrusions 231 and 232 come into close contact with the periphery of the receiving portion 15 in the lower molding surface 41 (refer to arrow 3).

[0128] In this embodiment, similar to the first and second embodiments, the molding pressure acts on the inner surfaces of flanges 222 and 223 (refer to arrow 4) in the width direction Y via the resin member 300 flowing into the inner space 220. Flanges 222 and 223 flex outward in the width direction Y, centered on their base ends (near the portion where the upper wall 204 is provided), thereby causing protrusions 231 and 232 to move downward (refer to arrow 7). This action increases the tightness of contact between protrusions 231 and 232 and the periphery of the receiving portion 15 (refer to arrow 3).

[0129] The protrusions 231 and 232 are in close contact with the outside of the receiving portion 15 rather than with the inner surface of the receiving portion 15, thereby blocking the cavity 40 from the gap 51. Therefore, it is possible to prevent the resin part 300 from curing inside the receiving portion 15 and outside the extrusion part 200, and the demolding resistance is further reduced.

[0130] Detailed illustrations are omitted, but the depth of the receiving portion 15 can be larger than the minimum permissible dimension of the length from the lower surface of the bottom wall 201 to the lower surface of the protrusions 231, 232. In this case, even if the extrusion 200 is formed within dimensional tolerances, the length from the lower surface of the bottom wall 201 to the lower surface of the protrusions 231, 232 may be smaller than the depth of the receiving portion 15. In this case, before the bottom wall 201 is seated on the inner bottom surface 16c, the lower surfaces of the protrusions 231, 232 abut against the lower forming surface 41. As the extrusion 200 moves further downward, the protrusions 235, 236 flex and deform. In the receiving state of the extrusion 200, the protrusions 231, 232 are in close contact with the periphery of the receiving portion 15. As a result, the pressure chamber 40 of the resin part 300 is blocked from the gap 51, and the inflow of the resin part 300 into the gap 51 can be further reliably suppressed.

[0131] (Fourth implementation) Hereinafter, the fourth embodiment will be described, focusing on the differences from the embodiments described above.

[0132] Reference Figure 15A and Figure 15B The metal-resin composite 100 is structurally formed as a rectangular box, comprising a rectangular frame portion 101 and a base plate portion 102 that closes the lower surface of the frame portion 101. The resin component 300 forms the base plate portion 102 and also constitutes the inner surface of the frame portion 101. The framework of the frame portion 101 is formed by joining four extruded components 200 into a rectangular frame shape.

[0133] Simultaneously refer to Figure 16 The extrusion member 200, like the embodiment described above, has a bottom wall 201, a pair of side walls 202 and 203, an upper wall 204, and a partition wall 205. However, the extrusion member 200 may also lack flanges 221 and 222. The extrusion member 200 as a whole has an L-shaped cross-section. The bottom wall 201 and the partition wall 205 extend outward in the width direction Y. Here, "outer side" refers to the side opposite to the inner side of the rectangular box-shaped frame portion 101. The extrusion member 200 has an outer wall 206 that connects the extensions of the bottom wall 201 and the partition wall 205 to each other in the height direction Z. The hollow 210 includes a third chamber 213 enclosed by the extensions of the bottom wall portion 201 and the partition wall 205, the lower part of the side wall 203, and the outer wall 206. The resin member 300 is overlapped on the outer surface of the side wall 202, forming the inner surface of the frame portion 101. The extrusion member 200 also has protrusions 231 and 232. Protrusion 231 is provided on the upper part of the extrusion member 200, and protrusion 232 is provided on the lower part of the extrusion member 200. However, the third chamber 213 and the outer wall 206 can be omitted, and the bottom wall 201 and the partition wall 205 may not extend from the side wall 203.

[0134] In this embodiment, protrusion 231 is provided at the corner of the side wall 202 and the upper wall 204, protruding upward from the corner. Protrusion 232 is provided at the corner of the side wall 202 and the bottom wall 201, protruding downward from the corner. Protrusions 231 and 232 have a wedge-shaped cross-section. Protrusion 231 has a pair of side surfaces and an upper surface, with the outer side inclined in the width direction. Protrusion 232 has a pair of side surfaces and an upper surface, with the outer side inclined in the width direction.

[0135] Reference Figure 17 In addition to the first mold 10 and the second mold 20, mold 2 also includes a third mold 30. The shoulder 12 is omitted from the first mold 10. The upper surface of the base 11 forms a lower forming surface 41, an extrusion part setting surface 16d, and a bottom mating surface 17. The lower forming surface 41 is formed in the center of the upper surface. The extrusion part setting surface 16d is formed as a rectangular frame surrounding the lower forming surface 41. The bottom mating surface 17 is formed as a rectangular frame surrounding the extrusion part setting surface 16d.

[0136] The second mold 20 has a main body 21 and a forming part 22. The forming part 22 is a cuboid smaller than the main body 21 and protrudes downward from the main body 21. The bottom surface of the forming part 22 forms a first upper forming surface 44. The four sides of the forming part 22 form inner forming surfaces 45. The rectangular frame-shaped stepped surface between the forming part 22 and the main body 21 forms a second upper forming surface 46. The four sides of the main body 21 form a first upper mating surface 24.

[0137] The third mold 30 is configured as a movable mold or an upper mold. The third mold 30 is formed in the shape of a rectangular frame and slides relative to the second mold 20. The outer edge of the lower surface of the third mold 30 forms a bottom mating surface 35. The third mold 30 has a recess 31, which is recessed upward on the lower surface of the third mold 30 and forms a receiving portion 15 together with the first mold 10. The recess 31 is formed in the shape of a mortar or an L-shape and gradually deepens from the outer edge. The recess 31 is defined by a first inner side surface 31a, a first inner bottom surface 31b, a second inner side surface 31c, and a second inner bottom surface 31d. The first inner side surface 31a extends upward from the inner periphery of the bottom mating surface 35. The first inner bottom surface 31b extends horizontally from the upper end of the first inner side surface 31a toward the inner side of the third mold 30. The second inner side surface 31c extends upward from the inner periphery of the first inner bottom surface 31b. The second inner bottom surface 31d extends horizontally from the upper end of the second inner side surface 31c toward the inner side of the third mold 30, and is continuous with the inner side surface of the third mold 30. The inner side surface of the third mold 30 forms the second upper mating surface 34.

[0138] In this embodiment, such as Figure 17As shown, with the second mold 20 and the third mold 30 retracted upwards, the extruder 200 is placed on the extruder placement surface 16d of the first mold 10. Next, as... Figure 18 As shown, the composite of resin part 300 is placed on the lower forming surface 41, and the third mold 30 is moved downward. This allows the extruded part 200 to be housed in the receiving portion 15 surrounded by the recess 31 and the extruded part setting surface 16d. In this housed state, forming pressure is applied to the extruded part 200 from the third mold 30 (refer to the hollow arrow). As a result, protrusion 231 comes into close contact with the second inner bottom surface 31d of the third mold 30, and protrusion 232 comes into close contact with the extruded part setting surface 16d of the first mold 10 (refer to the hollow arrow). Furthermore, even if the extruded part 200 bends or twists, the forming pressure corrects the elastic deformation of the extruded part 200, pushing the protrusions 231 and 232 integrally along the length direction X onto the molds 10 and 30.

[0139] If the extruded part 200 is held by the first mold 10 and the third mold 30, then as Figure 19 and Figure 20 As shown, the second mold 20 is moved downward to the bottom dead center. The second mold 20 is guided downward by the third mold 30. The chamber 40 is defined by the lower forming surface 41, the first upper forming surface 43, the inner forming surface, the second upper forming surface, and the outer surface of the side wall 202 of the extruder 200. The chamber 40 is blocked from the gap 51 between the surface of the extruder 200 and the inner surface of the receiving portion 15 (extruder mounting surface 16d, first inner side surface 31a, first inner bottom surface 31b, second inner side surface 31c, and second inner bottom surface 31d) by the close contact of the protrusions 231 and 232.

[0140] Therefore, in this embodiment, it is also possible to prevent the resin part 300 from unintentionally flowing into the gap 51 when filling the cavity 40 with the resin part 300. After molding, as Figure 21 As shown, the second mold 20 and the third mold 30 are retracted upwards. The extruded part 200 has an outer wall, thereby enabling easy demolding even with complex cross-sectional shapes.

[0141] (Fifth implementation) Hereinafter, the fifth embodiment will be described, focusing on the differences from the embodiments described above.

[0142] Reference Figure 21The metal-resin composite 100 is structurally similar to that of the fourth embodiment, having a frame portion 101 and a base plate portion 102. The skeleton of the frame portion 101 is formed by joining four extrusion members 200 into a rectangular frame shape. The resin member 300 forms not only the inner surface of the base plate portion 102 and the frame portion 101, but also the upper surface of the frame portion 101. Consequently, the shapes of the second mold 20, the third mold 30, and the chamber 40 differ from those of the fourth embodiment.

[0143] Simultaneously refer to Figure 22 The extrusion part 200 is also L-shaped as in the fourth embodiment and has protrusions 231 and 232. Protrusion 231 protrudes upward from the corner of the upper wall 204 and the side wall 203. Protrusion 232 protrudes inward in the width direction from the corner of the bottom wall 201 and the side wall 202. The lower surface of protrusion 232 is located slightly below the lower surface of the bottom wall 201 (which should be provided on the surface of the first mold 10).

[0144] The second inner bottom surface 31d of the third mold 30, in the fourth embodiment, has a width equal to the width of the upper wall 204. Referring to this... Figure 24 In this embodiment, the width has a plate thickness of 203. The extrusion 200 is disposed on the extrusion surface 16d of the first mold 10 in a state where the second mold 20 and the third mold 30 are retracted upwards.

[0145] Next, refer to Figure 25 The third mold 30 is moved downwards. As a result, the extruded part 200 is partially housed in the receiving portion 15, which is surrounded by the extruded part setting surface 16d and the recess 31. The upper wall 204 and side wall 202 are exposed from the receiving portion 15. At this time, the protrusion 231 comes into close contact with the second inner bottom surface due to the forming pressure of the third mold 30. The protrusion 232 is elastically deformed by the forming pressure and comes into close contact with the lower forming surface 41 or the extruded part setting surface 16d. Next, the composite of the resin part 300 is placed on the lower forming surface 41.

[0146] Then, as Figure 26 and Figure 27 As shown, the second mold 20 is moved to the bottom dead center. The chamber 40 is defined by the lower forming surface 41, the first upper forming surface 43, the inner forming surface 45, the second upper forming surface 46, the outer surface of the side wall 202 of the extruder 200, and the outer surface of the upper wall 204 of the extruder 200. The chamber 40 is blocked from the gap 51 between the surface of the extruder 200 and the inner surface of the receiving part 15 (extruder mounting surface 16d, first inner side surface 31a, first inner bottom surface 31b, and second inner side surface 31c) by the close contact of the protrusions 231 and 232.

[0147] Therefore, in this embodiment, it is also possible to prevent the resin component 300 from unintentionally flowing into the gap 51 when filling the cavity 40 with the resin component 300. Furthermore, referring to… Figure 28 It can easily demold the metal-resin composite 100.

[0148] (Sixth implementation) Hereinafter, the sixth embodiment will be described, focusing on the differences from the embodiments described above.

[0149] Reference Figure 29 The metal-resin composite 100 is structurally similar to that of the fourth and fifth embodiments, having a frame portion 101 and a base plate portion 102. The skeleton of the frame portion 101 is formed by joining four extrusion members 200 into a rectangular frame shape. The resin member 300 forms the inner surface of the base plate portion 102 and the frame portion 101, and also forms part of the upper surface of the frame portion 101. Consequently, the shapes of the second mold 20, the third mold 30, and the cavity 40 differ from those of the fourth embodiment.

[0150] Reference Figure 30 In the upper wall 204 of the extruder 200, the outer side in the width direction is higher than the inner side. The upper wall 204 has a low portion 204a extending inward in the width direction Y from the upper end of the side wall 202 and a high portion 204b extending outward in the width direction Y from the upper end of the side wall 203. The extruder 200 has a stepped portion 204c connecting the low portion 204a and the high portion 204b in the height direction. The protrusion 232 is the same as in the fifth embodiment. The protrusion 231 is provided in the stepped portion 204c and protrudes outward in the width direction Y from the corner of the high portion 204b and the stepped portion 204c. Thus, the protrusion 231 and the stepped portion 204c are integrally formed into a hook shape.

[0151] The second inner bottom surface 31d of the third mold 30, in the fourth embodiment, has a width equal to the width of the upper wall 204. Referring to this... Figure 31 In this embodiment, the extruder 200 has a width equivalent to the sum of the widths of the height 204b and the protrusion 231. The extruder 200 is disposed on the extruder placement surface 16d of the first mold 10 in a state where the second mold 20 and the third mold 30 are retracted upwards.

[0152] Next, as Figure 32As shown, the third mold 30 is moved downwards. This partially houses the extruder 200 within the receiving portion 15 formed by the extruder mounting surface 16d and the recess 31. The lower portion 204a of the upper wall 204 and the side wall 202 are exposed from the receiving portion 15. At this time, the protrusion 231 comes into close contact with the second inner bottom surface due to the forming pressure of the third mold 30. The protrusion 231 is formed in a hook shape, so it elastically deforms under the forming pressure and comes into close contact with the third mold 30 through its reaction force. The protrusion 232 also comes into close contact with the lower forming surface 41 or the extruder mounting surface 16d, similar to the fifth embodiment. Next, the composite of the resin part 300 is placed on the lower forming surface 41.

[0153] Then, as Figure 33 and Figure 34 As shown, the second mold 20 is moved to the bottom dead center. The chamber 40 is defined by the lower forming surface 41, the first upper forming surface 43, the inner forming surface 45, the second upper forming surface 46, the outer surface of the side wall 202 of the extruder 200, and the outer surface of the lower part 204a of the upper wall 204 of the extruder 200. The chamber 40 is blocked from the gap 51 between the surface of the extruder 200 and the inner surface of the receiving part 15 (extruder mounting surface 16d, first inner side surface 31a, first inner bottom surface, and second inner side surface) by the close contact of the protrusions 231 and 232.

[0154] Therefore, in this embodiment, it is also possible to prevent the resin component 300 from unintentionally flowing into the gap 51 when filling the cavity 40 with the resin component 300. Furthermore, referring to… Figure 35 It can easily demold the metal-resin composite 100.

[0155] The embodiments of the present invention have been described so far, but the above structure can be appropriately modified, added to, and deleted within the scope of the spirit of the present invention.

[0156] Explanation of reference numerals in the attached figures 1 Manufacturing apparatus 2. Mold 3 Drive Unit 4. Heating section 10. Mold No. 1 20 Mold No. 2 30. Mold No. 3 200 Extrusions 201 bottom wall Side walls 202 and 203 204 upper wall 205 partition wall 210 Hollow Room 211, Room 1 Room 212 220 interior space 221 Open at the top Flanges 222 and 223 224, 225 convex part 226, 227 Inner inclined surfaces 231, 232 protrusions 233, 234 Outer inclined surfaces

Claims

1. A method for manufacturing a metal-resin composite, comprising integrating a resin part with a metal extrusion part by pressure molding, characterized in that, have: Prepare a mold including a first mold and a second mold, wherein the first mold forms a receiving portion that accommodates at least a portion of the aforementioned extruded part, and the second mold is movable relative to the aforementioned first mold in an opening and closing direction; The aforementioned extruded part is housed in the aforementioned receiving portion, and the aforementioned resin part is disposed on the aforementioned first mold; and, The aforementioned second mold is moved in the mold closing direction to form a cavity defined by the outer surface of the aforementioned extruded part and the aforementioned mold, and the aforementioned resin part is pressurized and filled into the aforementioned cavity; The aforementioned extrusion has a hollow portion and a protrusion, the hollow portion containing a chamber, and the protrusion protruding from the outer surface of the aforementioned extrusion and adjacent to the aforementioned receiving portion when the aforementioned extrusion is received in the aforementioned receiving portion. In the aforementioned filling process, the forming pressure applied to the aforementioned extrusion from the aforementioned mold causes the aforementioned protrusion to come into close contact with the aforementioned receiving portion or its periphery, thereby blocking the aforementioned cavity from the gap between the inner surface of the aforementioned receiving portion and the outer surface of the aforementioned extrusion.

2. The method for manufacturing the metal-resin composite as described in claim 1, characterized in that, In the aforementioned filling process, the aforementioned forming pressure is applied to the aforementioned extrusion via the aforementioned resin component.

3. The method for manufacturing the metal-resin composite as described in claim 2, characterized in that, The aforementioned extrusion member has a pair of flanges that extend along the aforementioned inner surface of the aforementioned receiving portion in the aforementioned receiving state; The aforementioned protrusions are provided in pairs on each of the aforementioned pair of flanges; The aforementioned pair of flanges form an inner space between each other on their inner surfaces, and the aforementioned inner space constitutes part of the aforementioned chamber; In the aforementioned filling, the aforementioned resin component flowing into the aforementioned inner space applies the aforementioned forming pressure to the aforementioned pair of flanges, the aforementioned pair of flanges flex toward the aforementioned inner surface of the aforementioned receiving portion, and the aforementioned protrusions are in close contact with the aforementioned receiving portion or its periphery.

4. The method for manufacturing the metal-resin composite as described in claim 3, characterized in that, The aforementioned protrusions are provided on the outer surface of the aforementioned flange; In the filling of the aforementioned resin component, the aforementioned protrusion is in close contact with the aforementioned inner surface of the aforementioned receiving portion.

5. The method for manufacturing the metal-resin composite as described in claim 4, characterized in that, The aforementioned extrusion member has an inner inclined surface, which is disposed on at least one of the front ends of the aforementioned pair of flanges; The aforementioned inner inclined surface is inclined in the aforementioned receiving state in such a way that it moves away from the aforementioned receiving portion as it moves toward the base end side of the aforementioned pair of flanges.

6. The method for manufacturing the metal-resin composite as described in claim 5, characterized in that, The aforementioned extrusion member has a protrusion disposed at at least one of the front ends of the aforementioned pair of flanges, protruding toward the aforementioned inner space side beyond the inner surface of the flange; The aforementioned inner inclined surface is formed on the aforementioned protrusion.

7. The method for manufacturing the metal-resin composite as described in claim 3, characterized in that, The aforementioned extrusion member has a protruding piece that protrudes outward from at least one of the front ends of the aforementioned pair of flanges and is exposed from the aforementioned receiving portion in the aforementioned receiving state; The aforementioned protrusion is located at the front end of the aforementioned protruding piece; In the filling of the aforementioned resin component, the aforementioned protrusion is in close contact with the periphery of the aforementioned receiving portion.

8. The method for manufacturing the metal-resin composite as described in claim 7, characterized in that, The aforementioned protruding piece has a pressure-bearing surface that is perpendicular to the opening and closing direction of the aforementioned mold in the aforementioned contained state; The aforementioned protrusion is located at the front end of the aforementioned protruding piece and is opposite to the aforementioned peripheral portion in the aforementioned opening and closing direction.

9. The method for manufacturing the metal-resin composite as described in claim 1, characterized in that, The aforementioned mold also includes a third mold, which is movable relative to the aforementioned first mold in the opening and closing direction of the aforementioned mold, and together with the aforementioned first mold forms the aforementioned receiving part; The aforementioned protrusion protrudes in the aforementioned opening and closing direction in the aforementioned containment state, the aforementioned third mold contacts the aforementioned protrusion, and the aforementioned forming pressure is applied to the aforementioned extrusion from the aforementioned third mold.

10. The method for manufacturing the metal-resin composite as described in claim 9, characterized in that, The aforementioned protrusions are arranged in pairs on both sides of the aforementioned opening and closing direction of the aforementioned extrusion member. One of the aforementioned protrusions blocks the portion formed by the aforementioned extrusion member and the aforementioned first mold in the aforementioned gap from the aforementioned chamber, and the other of the aforementioned protrusions blocks the portion formed by the aforementioned extrusion member and the aforementioned third mold in the aforementioned gap from the aforementioned chamber.

11. The method for manufacturing the metal-resin composite as described in claim 10, characterized in that, The protrusion of the aforementioned one protrudes toward the surface of the aforementioned extrusion member that is disposed on the aforementioned first mold.

12. The method for manufacturing the metal-resin composite as described in claim 10 or 11, characterized in that, The aforementioned protrusion is provided on the stepped portion of the aforementioned extrusion to form a hook shape. The aforementioned third mold contacts the aforementioned protrusion and applies the aforementioned forming pressure to the aforementioned protrusion from the aforementioned third mold.

13. An apparatus for manufacturing a metal-resin composite, wherein a resin part is integrally formed with a metal extrusion part by pressure molding, characterized in that, have: The mold includes a first mold and a second mold, the first mold forming a receiving portion for at least partially receiving the aforementioned extruded part, and the second mold being movable relative to the aforementioned first mold; as well as The moving mechanism causes the aforementioned second mold to move; The aforementioned extrusion has a hollow portion and a protrusion, the hollow portion containing a chamber, and the protrusion protruding from the outer surface of the extrusion and adjacent to the aforementioned receiving portion when the aforementioned extrusion is received in the aforementioned receiving portion. If the second mold is moved by the aforementioned moving mechanism while the aforementioned resin part is positioned on the aforementioned first mold, a cavity is formed by the surface of the aforementioned extruder and the aforementioned mold. The aforementioned resin part is pressurized and filled into the aforementioned cavity, and the aforementioned protrusion is brought into close contact with the aforementioned receiving portion or its periphery by the forming pressure applied to the aforementioned extruder from the aforementioned mold. The aforementioned cavity is blocked by the gap between the inner surface of the aforementioned receiving portion and the outer surface of the aforementioned extruder.

14. A method for manufacturing a metal-resin composite, wherein a resin part is integrally formed with a metal extrusion part by pressure molding, characterized in that, have: Prepare a mold including a first mold and a second mold, wherein the first mold forms a receiving portion that accommodates at least a portion of the aforementioned extruded part, and the second mold is movable relative to the aforementioned first mold in an opening and closing direction; The aforementioned extruded part is housed in the aforementioned receiving portion, and the aforementioned resin part is disposed on the aforementioned first mold; and, The second mold is moved in the mold closing direction to form a cavity defined by the surface of the extruded part and the mold, and the resin part is pressurized and filled into the cavity. The aforementioned extrusion has a protrusion that protrudes from the aforementioned surface and is adjacent to the aforementioned receiving portion when the aforementioned extrusion is received in the aforementioned receiving portion. In the aforementioned filling process, the forming pressure applied to the aforementioned extrusion from the aforementioned mold causes the aforementioned protrusion to come into close contact with the aforementioned receiving portion or its periphery, thereby blocking the aforementioned cavity from the gap between the inner surface of the aforementioned receiving portion and the aforementioned surface of the aforementioned extrusion. In the aforementioned filling process, the aforementioned forming pressure is applied to the aforementioned extruded component via the aforementioned resin component. The aforementioned extrusion member has a pair of flanges that extend along the aforementioned inner surface of the aforementioned receiving portion in the aforementioned receiving state; The aforementioned protrusions are provided in pairs on each of the aforementioned pair of flanges; The aforementioned pair of flanges form an inner space between each other on their inner surfaces, and the aforementioned inner space constitutes part of the aforementioned chamber; In the aforementioned filling, the aforementioned resin component flowing into the aforementioned inner space applies the aforementioned forming pressure to the aforementioned pair of flanges, the aforementioned pair of flanges flex toward the aforementioned inner surface of the aforementioned receiving portion, and the aforementioned protrusions are in close contact with the aforementioned receiving portion or its periphery.

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