METHOD AND DEVICE FOR PRODUCING A METAL-RESIN COMPOSITE STRUCTURE

Abstract

Method for producing a metal-resin composite structure (100) in which a resin material (300) is integrated with an extruded material (200) made of metal by compression molding, the method comprising: Preparing a forming tool (2) comprising a first forming tool (10) forming a receiving section (15) which receives at least a part of the extruded material (200) and a second forming tool (20) which is movable in an opening and closing direction with respect to the first forming tool (10); Receiving the extruded material (200) in the receiving section (15) and arranging the resin material (300) on the first mold tool (10); and Moving the second mold tool (20) in a mold tool closing direction to form a cavity (40) defined by a surface of the extruded material (200) and the mold tool (2), and filling the cavity (40) with the resin material (300) by applying pressure to the resin material (300), wherein the extruded material (200) has a protrusion (231, 232) that projects from the surface and approaches the receiving section (15) in a receiving state in which the extruded material (200) is received in the receiving section (15), and the protrusion (231, 232) is caused by the forming pressure exerted by the forming tool (2) on the extruded material (200) during filling to come into close contact with the receiving section (15) or an edge section thereof, and the cavity (40) is separated by a gap (51) between an inner surface of the receiving section (15) and the surface of the extruded material (200).

Description

Technical field

[0001] The present invention relates to a device and a method for producing a metal-resin composite structure. State of the art

[0002] For a metal-resin composite structure applied to structural components, such as a vehicle frame, various structures and manufacturing processes have been proposed. For example, in a composite structure disclosed in patent document 1, a thermosetting carbon fiber reinforced resin (CFRP) is bonded with an adhesive to a surface of extruded aluminum material. In a composite structure disclosed in patent document 2, CFRP is hot-pressed onto an aluminum sheet to integrate the aluminum sheet and CFRP. Patent document 3 describes a method for manufacturing a composite structure formed from a metal element and a fiber-reinforced plastic material. Patent document 4 describes a metal-plastic composite body in which a metal plate and a fiber-reinforced plastic are integrally bonded with an adhesive.Patent document 5 describes a method for manufacturing sealing rings with at least one and preferably two sealing lips adhering to a carrier body, which may optionally consist of different materials. Document listPatent documents Patent Document 1: JP 2017-119422 A Patent Document 2: JP 2020-104411 A Patent document 3: DE 10 2018 106 709 A1 Patent document 4: JP 2021 - 91 140 A Patent document 5: DE 28 30 247 A1 Summary of the invention: Technical problem

[0003] In a case where the hot pressing process, exemplified in patent document 2, is applied to the production of a composite structure containing extruded aluminum material, it is assumed that a die is required to be manufactured such that a suitable gap is formed between the die and the extruded aluminum material. This die is assumed to have a reference dimension that takes into account the tolerance of the extruded aluminum material. This allows the extruded aluminum material, formed within the tolerance, to be positioned appropriately in the die during each production run of the composite structure. Alternatively, the extruded aluminum material is hot extruded as described in patent document 1.For this reason, twisting and bending are likely to occur during extrusion, and it is difficult to improve the dimensional accuracy of the extruded aluminum material.

[0004] Given the low dimensional accuracy of the extruded aluminum material, the gap between the die and the extruded aluminum is expected to be considerably larger than the gap between mating die surfaces. During hot pressing, resin material unintentionally flows into this gap, reducing the manufacturing efficiency of the composite structure. For example, if the resin material solidifies in the gap, the die separation resistance increases. After die separation, a complex process is required to remove the excess resin material that has solidified in the gap. To prevent a shortage of resin on the extruded aluminum, it is necessary to provide an additional quantity of resin beforehand to anticipate any excess resin that may be removed.

[0005] One object of the present invention is to prevent the flow of a resin material into a gap between a molding tool and an extruded material during the production of a metal-resin composite structure by compression molding the resin material onto the extruded material. Solution to the problem

[0006] A first aspect of the present invention provides a method for producing a metal-resin composite structure in which a resin material is integrated with an extruded metal material by compression molding. The method comprises preparing a mold, which includes a first mold forming a receiving section that receives at least a portion of the extruded material, and a second mold movable in an opening and closing direction relative to the first mold; receiving the extruded material in the receiving section and arranging the resin material on the first mold; and moving the second mold in a mold closing direction to form a cavity defined by a surface of the extruded material and the mold, and filling the cavity with the resin material by applying pressure to the resin material.The extruded material has a protrusion that extends from the surface and approaches the receiving section in a receiving state where the extruded material is received in the receiving section, and the protrusion is brought into close contact with the receiving section or an edge section of the receiving section by the forming pressure exerted on the extruded material by the forming tool during filling, and the cavity is separated by a gap between an inner surface of the receiving section and the surface of the extruded material.

[0007] According to the above setup, the protrusion provided on the extruded material is brought into close contact with the mold by means of the forming pressure exerted on the extruded material during cavity formation, thus separating the cavity from the gap between a surface of the extruded material and an inner surface of the receiving section. This prevents the resin material from unintentionally flowing from the cavity into the gap between the extruded material and the mold.

[0008] During filling, the shaping pressure can be exerted on the extruded material via the resin material.

[0009] According to the above setup, the cavity can be separated from the gap using pressure exerted by the resin material on the extruded material.

[0010] The extruded material can have a pair of flanges extending along the inner surface of the receiving section in the receiving state; a pair of protrusions can be provided on the pair of flanges; the pair of flanges can form an interior space between the inner surfaces of the flanges, and the interior space can form part of the cavity; and during filling, the forming pressure can be exerted on the pair of flanges via the resin material that has flowed into the interior space; the pair of flanges can be deformed towards the inner surface of the receiving section, and the protrusion can be brought into close contact with the receiving section or the edge section of the receiving section.

[0011] According to the above setup, by flowing the resin material into a pair of flanges, a structure is created in which the extruded material is deformed using the pressure of the resin material. When the resin material filled into the interior is integrated with the extruded material, the contact area between the resin and the extruded material is increased, and the resin material is bonded more firmly to the extruded material.

[0012] The protrusion can be provided on an outer surface of the flange, and when filling with the resin material, the protrusion can come into close contact with the inner surface of the receiving section.

[0013] According to the above setup, the resin material exerts pressure in one direction of the flange's thickness. Since the protrusion comes into close contact with the receiving section along the direction of the pressure, the gap can be easily eliminated.

[0014] The extruded material may have an inclined inner surface provided on at least one of the tip sections of a pair of flanges, and the inclined inner surface is inclined such that it is separated from the receiving section, towards one side of the base end of the pair of flanges in the receiving state.

[0015] According to the above setup, when the resin material flows into the interior, when the resin material acts on an inclined inner surface in a mold closing direction, the inclined inner surface is pressed by a wedge effect in a direction of approach to the receiving section. This makes it even easier to deform the flange in the direction of the receiving section and simply closes the gap.

[0016] The extruded material may have a projecting section provided on at least one of the tip sections of the pair of flanges and projecting further towards the interior side than an interior surface of the flange, and the inclined interior surface is formed on the projecting section.

[0017] According to the above setup, the resin material is crimped onto the protruding section and the bond strength of the resin material to the extruded material is improved.

[0018] The extruded material can have a pair of inclined outer surfaces provided on the side of a lower surface of at least one of a pair of protrusions and inclined such that they are separated from the receiving section in a receiving direction of the extruded material into the receiving section in the receiving state, and during receiving of the extruded material, the flange can be deformed due to the contact of the inclined outer surface with the receiving section to the inner side, and the protrusion can come into close contact with the inner surface of the receiving section by an elastic force of the flange.

[0019] According to the above setup, the extruded material can be received while the flange is deformed by a wedge effect of the inclined outer surface towards the inner surface. The protrusion can also be brought into close contact with the receiving section using a reaction force due to elastic deformation of the flange, and the gap can be closed more reliably.

[0020] The extruded material may have a protruding part that extends from at least one of the tip sections of a pair of flanges to the outside of the flange and is exposed from the receiving section in the receiving state; the protrusion may be provided at a tip section of the protruding part and the protrusion may be brought into close contact with the edge section of the receiving section when filling with the resin material.

[0021] According to the above design, since the gap outside the intake section is closed, an undesirable inflow of resin material can be reduced.

[0022] The projecting part can have a pressure-receiving surface perpendicular to the opening and closing direction of the mold in the receiving state, and the protrusion can be provided at a tip section of the projecting part and directed towards the edge section in the opening and closing direction.

[0023] According to the above design, the protruding part is pressed against an edge section of the receiving section not only by deformation of the flange, but also by a forming pressure acting on the protruding part itself. For this reason, the contact of the protrusion is improved and the gap can be closed more reliably.

[0024] The forming tool may further comprise a third forming tool which is movable in the opening and closing direction of the forming tool relative to the first forming tool and which forms the receiving section together with the first forming tool, and the protrusion may project in the opening and closing direction in the receiving state and the third forming tool may come into contact with the protrusion in such a way that the forming pressure is exerted by the third forming tool on the extruded material.

[0025] According to the above design, since the third forming tool, which is movable in the opening and closing directions, also forms the receiving section, the introduction of the extruded material into the forming tool and the separation or release of the extruded material can be carried out easily, even if the cross-sectional shape of the extruded material is complex. In this case, the forming pressure of the third forming tool is exerted directly on the protrusion. This locally generates the surface pressure in the protrusion and brings the protrusion into close contact with the receiving section. For this reason, the gap can be easily closed.

[0026] A pair of protrusions can be provided on both sides in the opening and closing direction of the extruded material, with one of the protrusions being able to separate a section formed by the extruded material and the first forming tool from the gap, and the other of the protrusions being able to separate a section formed by the extruded material and the third forming tool from the gap.

[0027] According to the above setup, both the gap of the first forming tool and the gap of the second forming tool can be closed by utilizing the forming pressure of the third forming tool.

[0028] One of the protrusions can protrude in a direction that approaches the first forming tool in relation to a surface of the extruded material that is present on the first forming tool.

[0029] According to the above setup, one of the protrusions can be easily brought into close contact with the first mold by utilizing the forming pressure of the third molding tool, and the gap can be closed more reliably.

[0030] The other of the protrusions can be provided in a stepped section that is provided in a hook shape on the extruded material, and the third forming tool can come into contact with the other of the protrusions in such a way that the forming pressure is exerted by the third forming tool on the other of the protrusions.

[0031] According to the above setup, by deforming the hook-shaped step section using the forming pressure from the third forming tool, the other of the protrusions can be brought into close contact with the third forming tool. Therefore, the gap can be closed more reliably.

[0032] A second aspect of the present invention provides a device for producing a metal-resin composite structure in which a resin material is integrated with an extruded metal material by compression molding. The device comprises a first mold forming a receiving section that partially receives the extruded material, a second mold being movable relative to the first mold, and a movement mechanism that moves the second mold.The extruded material has a protrusion that extends from a surface of the extruded material and approaches the receiving section in a receiving state where the extruded material is received in the receiving section. When the second forming tool is moved by the movement mechanism into a state where the resin material is positioned on the first forming tool, a cavity defined by a surface of the extruded material and the forming tool is formed. The resin material is pressurized so that it fills the cavity. The protrusion is brought into close contact with the receiving section or an edge of the receiving section by the forming pressure exerted on the extruded material by the forming tool, and the cavity is separated by a gap between an inner surface of the receiving section and the surface of the extruded material. Advantageous effects of the invention

[0033] According to the present invention, the flow of a resin material into a gap between a molding tool and an extruded material during the production of a metal-resin composite structure can be prevented by compression molding the resin material onto the extruded material. Brief description of the drawings Fig. Figure 1A is a top view of a metal-resin composite structure produced by a manufacturing apparatus and a method according to a first embodiment of the present invention; Fig. 1B is a cross-sectional view along line BB in the Fig. 1A; Fig. 2A is a cross-sectional view of the manufacturing device according to the first embodiment; Fig. 2B is a cross-sectional view along line BB in the Fig. 2A; Fig. Figure 3 is a concept diagram of the manufacturing process according to the first embodiment; Fig. Figure 4 is a cross-sectional view of an extruded material that has been prepared for the manufacture of the metal-resin composite structure according to the first embodiment; Fig. Figure 5 is a concept diagram of the manufacturing process according to the first embodiment; Fig. Figure 6 is a concept diagram of the manufacturing process according to the first embodiment; Fig. Image 7 is a partially enlarged view of Fig. 6; Fig. 8 is a view that the Fig. 4 corresponds to a second embodiment; Fig. 9 is a view that the Fig. 3 in the second embodiment corresponds; Fig. 10 is a view that the Fig. 7 in the second embodiment corresponds; Fig. Figure 11 is a cross-sectional view of the metal-resin composite structure produced by the manufacturing device and method according to a third embodiment; Fig. 12 is a view that the Fig. 3 corresponds to the third embodiment; Fig. 13 is a view that the Fig. 6 in the third embodiment corresponds; Fig. 14 is a view that the Fig. 7 in the third embodiment; Fig. Figure 15A is a top view of the metal-resin composite structure produced by the manufacturing apparatus and method according to a fourth embodiment; Fig. 15B is a cross-sectional view along line BB in the Fig. 15A; Fig. Figure 16 is a cross-sectional view of an extruded material that has been prepared for the manufacture of the metal-resin composite structure according to the fourth embodiment; Fig. Figure 17 is a concept diagram of the manufacturing device and the manufacturing process according to the fourth embodiment; Fig. Figure 18 is a concept diagram of the manufacturing process according to the fourth embodiment; Fig. Figure 19 is a concept diagram of the manufacturing process according to the fourth embodiment; Fig. 20 is a concept diagram of the manufacturing process according to the fourth embodiment; Fig. 21 is a concept diagram of the manufacturing process according to the fourth embodiment; Fig. 22 is a view that the Fig. 15B in a fifth embodiment; Fig. 23 is a view that the Fig. 16 corresponds to the fifth embodiment; Fig. 24 is a view that the Fig. 17 corresponds to the fifth embodiment; Fig. 25 is a view that the Fig. 18 corresponds to the fifth embodiment; Fig. 26 is a view that the Fig. 19 corresponds to the fifth embodiment; Fig. 27 is a view that the Fig. 20 corresponds to the fifth embodiment; Fig. 28 is a view that the Fig. 21 corresponds to the fifth embodiment; Fig. 29 is a view that the Fig. 15B in the fifth embodiment corresponds; Fig. 30 is a view that the Fig. 16 corresponds to the fifth embodiment; Fig. 31 is a view that the Fig. 17 corresponds to the fifth embodiment; Fig. 32 is a view that the Fig. 18 corresponds to the fifth embodiment; Fig. 33 is a view that the Fig. 19 corresponds to the fifth embodiment; Fig. 34 is a view that the Fig. 20 in the fifth embodiment corresponds; and Fig. 35 is a view that the Fig. 21 corresponds to the fifth embodiment. Description of embodiments

[0034] Embodiments of the present invention are described with reference to the drawings. In the drawings, identical or corresponding elements are designated by the same reference numerals, and any duplicate description is omitted.

[0035] In a manufacturing device 1 and a manufacturing process for a metal-resin composite structure 100, a resin material 300 is integrated with an extruded material 200, which is made of metal, by compression molding using a mold 2 (see the Fig. 1A and Fig. 2A). An X-direction in the diagram corresponds to an extrusion direction or a longitudinal direction of the extruded material 200. The term "cross-section" simply refers to a cross-section orthogonal to the X-direction. A Y-direction is a direction within a cross-section and corresponds to a width direction of the extruded material 200. A Z-direction is orthogonal to the Y-direction in a cross-section, corresponds to a height direction of the extruded material 200, and also corresponds to an opening and closing direction of the die 2. Since the Z-direction is upward and downward in some diagrams, for the sake of convenience, the Z-direction is defined as vertical and the XY directions are defined as horizontal. The top (+Z-direction) corresponds to a die opening direction M1, and the bottom (-Z-direction) corresponds to a die closing direction M2.However, this is an example and the positions of the metal-resin composite structure 100 and a component element of the metal-resin composite structure 100 and the manufacturing device 1 and a component element of the manufacturing device 1 can be changed in a suitable manner. (First embodiment)

[0036] With reference to the Fig. 1A and Fig. 1B comprises the metal-resin composite structure 100 according to a first embodiment, the extruded material 200, which is made of metal, and the resin material 300, which is provided on the extruded material 200. The metal-resin composite structure 100 is expediently applied to a structural component, such as a vehicle body frame of a motor vehicle.

[0037] The metal material of extruded material 200 is not specifically limited. Lightweight alloys, such as aluminum and magnesium alloys, are preferred examples and contribute to both weight reduction and high stiffness of a structural component. Below, extruded material 200 is shown as being made from an aluminum alloy only as an example.

[0038] Although not shown in detail, the extruded material 200 is obtained by heating and compressing a block-shaped metal material within the main body of an extruder and extruding the block-shaped metal material through a die attached to the main body. After extrusion from the die, necessary processing, such as cooling, picking, and cutting, is performed. Since the cross-section of the extruded material 200 is determined by the shape of the die, it is uniform in the longitudinal X direction. However, twisting or bending occurs during the thermoforming process. Elements of the extruded material 200 extend in the longitudinal X direction and are seamlessly integrated with one another.

[0039] The resin material 300 is obtained by compression molding a composite material in the manufacturing device 1 (see the Fig. 2A and Fig. 2B). The composite material can be a layered composite (SMC), formed in a layered mold, or a bulk composite (BMC), formed in a bulk mold. The SMC or BMC is realized from a fiber-reinforced plastic (FRP) in which a matrix resin is impregnated with fibers. The matrix resin contains a thermosetting resin, such as an unsaturated polyester, as a main component, and an additive is mixed into the main component. The additive includes, for example, a mold release agent. The fibers are, for example, glass fibers or carbon fibers that are cut short and oriented in a random direction within the composite material. However, the resin material 300 is not limited to a thermosetting resin and can be a thermoplastic resin. Below, the resin material 300 is produced from SMC only as an example.

[0040] In the present embodiment, the extruded material 200 has a rectangular cross-section. One long side of the rectangle extends in the vertical direction Z, and one short side extends in the horizontal direction Y. The resin material 300 is provided on an upper section of the extruded material 200 and is formed in a plate shape with a width greater than that of the extruded material 200. A cross-section of the metal-resin composite structure 100 is T-shaped and is line-symmetric about a center line in the horizontal direction. Cross-sections of the extruded material 200 and the resin material 300 are correspondingly line-symmetric.

[0041] It should be noted that the top-view shape of the resin material 300 is not specifically restricted. The top-view shape is merely an example of a rectangular shape, in which one long side extends in the longitudinal direction X and one short side extends in the transverse direction Y, wherein the short side of the resin material 300 is aligned with both ends in the longitudinal direction X of the extruded material 200, and the cross-section of the metal-resin composite structure 100 is uniform in the longitudinal direction X.

[0042] With reference to the Fig. 2A and Fig. 2B comprises the manufacturing device 1, primarily the mold 2, a drive unit 3, and a heating unit 4. The mold 2 comprises a first mold 10 and a second mold 20. The first mold 10 is configured as a stationary 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 arranged above the first mold 10 (i.e., in the mold opening direction M1) and is movable in the vertical direction (i.e., in the opening and closing direction) relative to the first mold 10.

[0043] The first mold 10 has a base section 11 and a shoulder section 12. An upper surface of the base section 11 forms a horizontal lower forming surface 41. The shoulder section 12 projects upward from an edge section of the base section 11, and an inner surface of the shoulder section 12 extends upward from the lower forming surface 41. The inner surface of the shoulder section 12 is equivalent to the top-view shape of the resin material 300 of the metal-resin composite structure 100 in a cross-section (not shown in detail) perpendicular to the opening and closing direction. In the present example, since the top-view shape of the resin material 300 is a rectangular shape (see the Fig. 1A), the shoulder section 12 in a top view has a rectangular window frame shape, as shown in the Fig. 2A and Fig. 2B is evident. A lower section of the inner surface of the shoulder section 12 forms a vertical side-shaping surface 42. An upper section of the inner surface of the shoulder section 12 forms a lower fitting surface 14.

[0044] The first forming tool 10 has a receiving section 15 that receives the extruded material 200. The receiving section 15 is provided as a recess in the lower forming surface 41. The receiving section 15 has a U-shaped inner surface 16 and is designed as a groove that opens towards the lower forming surface 41. The inner surface 16 of the receiving section 15 comprises a pair of inner surfaces 16a and 16b that extend continuously downwards with the lower forming surface 41, and an inner lower surface 16c that connects the inner surfaces 16a and 16b horizontally.

[0045] The second forming tool 20 has a main body section 21. The main body section 21 has, for example, a rectangular parallelepiped shape. A lower surface of the main body section 21 forms an upper forming surface 43, which is oriented towards the lower forming surface 41 in the opening and closing direction. A side surface of the main body section 21 forms an upper fitting surface 24, which extends upward from a boundary edge of the lower forming surface 41. The upper fitting surface 24 is similar to, and slightly smaller than, a cross-section of the inner surface of the shoulder section 12 in a cross-section (not shown in detail) perpendicular to the opening and closing direction. For convenience, this distance is exaggerated in the diagram.

[0046] The drive unit 3 moves the second mold 20 in the opening and closing direction between a retracted position (see the solid line) and a bottom dead center (see a two-dot dashed line). The heating unit 4 heats the mold 2.

[0047] Below is a method for producing the metal-resin composite structure 100 (see the Fig. 1A) using the manufacturing device 1 is described. In addition, the structures of the mold 2, the extruded material 200, the resin material 300 and the metal-resin composite structure 100 are also described.

[0048] With reference to the Fig. 3. The mold 2 is configured as described above and below and is prepared in the manufacturing device 1. Furthermore, in each production run of the metal-resin composite structures 100, a composite material of the extruded material 200 and the resin material 300 is produced. The second mold 20 is positioned in the retracted position. In this retracted state, the upper forming surface 43 is sufficiently separated upwards from the upper end surface of the first mold 10 to facilitate the insertion of the extruded material 200 and the composite material and the removal of the metal-resin composite structure 100.

[0049] With reference to the Fig. Figure 4 shows that the extruded material 200 to be prepared has a lower wall 201, a pair of side walls 202 and 203, and an upper wall 204. One pair of side walls 202 and 203 extends in the vertical direction Z by forming long sides of a rectangular cross-section, and the lower wall 201 and the upper wall 204 extend in the horizontal direction Y by forming short sides of the rectangular cross-section. One pair of side walls 202 and 203 is arranged vertically upwards from a pair of side edges of the lower wall 201. The upper wall 204 connects the upper sections of the side walls 202 and 203.

[0050] The extruded material 200 has a cavity 210, defined by an inner surface of the walls 201 to 204, and one or more partition walls 205 that divide(s) the cavity 210. The cavity 210 is open at both ends in the longitudinal direction X. In the present embodiment, the partition wall 205 is a single unit connecting inner surfaces of the side walls 202 and 203 between the lower wall 201 and the upper wall 204 in the vertical direction Z, and the cavity 210 is divided in the vertical direction Z by the partition wall 205 into a first chamber 211 and a second chamber 212. However, multiple partition walls can be arranged at intervals in the vertical direction Z, or the partition wall can be omitted.

[0051] The extruded material 200 has a pair of flanges 222 and 223. The pair of flanges 222 and 223 is a section extending upwards from a pair of sidewalls 202 and 203. An outer surface of the flange 222 is substantially flush with an outer surface of the sidewall 202 and forms the entire outer surface of the extruded material 200 together with an outer surface of the sidewall 202. The thickness of the flange 222 is equal to, less than, or greater than the thickness of the sidewall 202. The relationship between the flange 223 and the sidewall 203 is as described above.

[0052] The extruded material 200 has an interior space 220 defined by an outer surface (i.e., a top surface) of the upper wall 204 and the inner surfaces of a pair of flanges 222 and 223. The interior space 220 is open both in the longitudinal direction X and upwards. Top sections (i.e., upper end sections) in the vertical direction Z of a pair of flanges 222 and 223 form an opening 221 of the interior space 220.

[0053] The extruded material 200 has a pair of projecting sections 224 and 225 provided at the tips of a pair of flanges 222 and 223. Each of the projecting sections 224 and 225 extends inward in the width direction Y from the tips of the corresponding flanges 222 and 223. In other words, the projecting sections 224 and 225 extend in such a way that they approach the interior 220. This narrows the upper opening 221 compared to the case where neither of the projecting sections 224 and 225 is present. Furthermore, a lower surface of the projecting sections 224 and 225 faces the interior 220.

[0054] The extruded material 200 has inclined inner surfaces 226 and 227, which are provided at the tip sections (in the present embodiment, in particular a pair of the projecting sections 224 and 225) of a pair of flanges 222 and 223. The inclined inner surfaces 226 and 227 connect a top surface and a side surface of the projecting sections 224 and 225 and are inclined towards the inside in the width direction Y in the direction of the bottom. Viewed from the projecting sections 224 and 225, the bottom corresponds to the side of the base end of the flanges 222 and 223 and also corresponds to the die closing direction M2. The inside corresponds to the side of the interior 220 and also corresponds to the side furthest from the receiving section 15.

[0055] The extruded material 200 has protrusions 231 and 232 that project from a surface of the extruded material 200. In the present embodiment, the protrusions 231 and 232 form a pair in the lateral direction Y. One pair of protrusions 231 and 232 is provided on the outer surfaces of a pair of flanges 222 and 223, and these project outwards in the lateral direction Y from one pair of flanges 222 and 223.

[0056] In particular, in the present embodiment, a pair of protrusions 231 and 232 are provided at the tip sections of a pair of flanges 222 and 223, respectively. The protrusion 231 and the projecting section 224 are integrated into a tip section of the flange 222, project from the tip section on both sides in the lateral direction Y, and form a common upper surface that is wider than one plate thickness of the flange 222. The same applies to a relationship between the protrusion 23, the projecting section 225, and the flange 223.

[0057] Next, with reference to the Fig. 3 and Fig. 4. The prepared extruded material 200 is received in the receiving section 15. The manufactured composite material of the resin material 300 is then placed on the first mold 10. The extruded material 200 and the composite material can be inserted manually. The manufacturing device 1 can include a robot for inserting the extruded material 200 and the composite material.

[0058] The width of the receiving section 15 is defined as the distance between the inner surfaces 16a and 16b in the lateral direction Y. The depth of the receiving section 15 is defined as the length in the opening and closing directions from the lower forming surface 41 to the inner lower surface 16c. The width of the extruded material 200 is defined as the distance between the end surfaces of the protrusions 231 and 232 in the lateral direction Y. The height of the extruded material 200 is defined as the length in the vertical direction Z from a lower surface of the lower wall 201 to an upper surface (i.e., a common upper surface of the protrusions 231 and 232 and the projecting sections 224 and 225) of the flanges 221 and 222. A difference between the maximum and minimum permissible dimensions is defined as the dimensional tolerance. The dimensional tolerance of the extruded material 200 is, for example,within a range of 0.5 to 1.0 mm. In addition to the dimensional tolerance, the extruded material 200 can be formed taking into account geometric tolerances, such as the flatness of the lower surface of the bottom wall 201 and the outer surface of the side walls 202 and 203. The prepared extruded material 200 has been formed within the tolerance.

[0059] When picking up the extruded material 200, it is inserted into the receiving section 15 in an insertion position with its lower wall 201 facing downwards. The width of the receiving section 15 is identical to the maximum permissible width of the extruded material 200. Therefore, the extruded material 200, which has been formed within the dimensional tolerance, can move downwards in the receiving section 15 without coming into contact with it.

[0060] The extruded material 200 is simply inserted until the lower wall 201 rests on the inner lower surface 16c, ensuring that the extruded material 200 does not come into contact with the receiving section 15 and that its own weight acts. The depth of the receiving section 15 is greater than the maximum permissible height of the extruded material 200. Therefore, when the extruded material 200 is inserted, the entire extruded material 200 is contained within the receiving section 15, and an upper surface of the extruded material 200 is positioned slightly below the lower forming surface 41. A side surface of the protrusions 231 and 232 is oriented with a very small gap towards an upper end section of an inner surface of the receiving section 15.Below the protrusions 231 and 232, a gap 51 is formed between the inner surface 16 of the receiving section 15 and a surface of the extruded material 200 (for example, an outer surface of the side walls 202 and 203, a lower surface of the lower wall 201 and the like).

[0061] With reference to the Fig. 3 Next, the mold 2 is preheated by the heating unit 4 such that the temperature of the mold 2 is increased to a predetermined temperature. Next, a composite material (for example, SMC) of the resin material 300 is placed on the lower mold surface 41 and covers the extruded material 200, which is held in the receiving section 15, from above.

[0062] Next, with reference to the Fig. 5. The drive unit 3 moves the second mold 20 in the mold closing direction M2 (downwards) from the retracted position to the bottom dead center. In a downward movement of the second mold 20, the main body section 21 is internally aligned with the shoulder section 12, and the upper mating surface 24 is aligned with the lower mating surface 14 with a small mold gap 52. The second mold 20 is guided through the shoulder section 12 and slides downwards. The second mold 20 pushes the resin composite material 300 downwards. The composite material is softened by the heat of the mold 2 and flows under pressure from the forming force exerted by the second mold 20.

[0063] With reference to the Fig. In a bottom dead center (BDC) state, where the second mold 20 is positioned at BDC, the upper forming surface 43 and the lower forming surface 41 are separated from each other in the opening and closing directions. The lower mating surface 14 is a section of an inner surface of the shoulder section 12 that is located more towards the top than the upper forming surface 43 in the BDC state of the second mold 20. The side forming surface 42 is a section of the inner surface of the shoulder section 12 that is located more towards the bottom than the upper forming surface 43 in the BDC state of the second mold 20. The lower forming surface 41, the side forming surface 42, and the upper forming surface 43 define a cavity 40 that is to be filled with the composite material.

[0064] The cavity 40 is connected to the interior of the receiving section 15, which is formed in the lower forming surface 41, and to the interior space 220 via the upper opening 221 of the extruded material 200 in the receiving section 15. The interior space 220 is intended to be filled with the resin material 300. In other words, the interior space 220 forms part of the cavity 40, and the cavity 40 is also defined by a surface of the extruded material 200. The cavity 40 is connected to the mold cavity 52. ​​Like the mold cavity 52, the cavity 51 is not intended to be filled with the resin material 300.

[0065] In this regard, also with reference to the Fig. 7. The resin material 300 is forced into the receiving section 15 by being pressed during a downward movement of the second mold tool 20 (see arrow 1). Once the resin material 300 reaches the same level as an upper surface of the extruded material 200 in the opening and closing directions, the upper opening 221 and a space between the protrusions 231 and 232 and the inner surface 16 of the receiving section 15 are assumed to be the flow path of the resin material 300. However, since this space has a much higher inflow resistance than the upper opening 221, it is likely that the resin material 300 passes through the upper opening 221.

[0066] The resin material 300 exerts a downward pressure based on the forming pressure (see arrow 1) exerted by the second mold 20 (see arrow 2) on the inclined inner surfaces 226 and 227. This causes the projecting sections 224 and 225 to be pressed outwards in the lateral direction Y by a wedge effect, and the flanges 222 and 223 to be elastically deformed outwards in the lateral direction Y (see arrow 3). Furthermore, the resin material 300, flowing into the interior 220, forms a surface that defines the interior 220 (see arrow 4), based on the forming pressure exerted by the second mold 20, which deforms the flanges 222 and 223 outwards in the lateral direction Y (see arrow 3). However, the inclined inner surfaces 226 and 227 can be omitted and an end surface of the projecting sections 224 and 225 can be connected perpendicularly to an upper surface.Even in this case, this forming pressure can be applied perpendicularly to an inner surface of an end section and deformation of the flanges 222 and 223 in the direction of arrow 3 can be promoted.

[0067] This brings the protrusions 231 and 232 into close contact with the inner surfaces 16a and 16b of the receiving section 15, respectively (see arrow 3). The deformation direction of the flanges 222 and 223 is along the perpendicular direction of the inner surfaces 16a and 16b. Therefore, the protrusions 231 and 232 are easily brought into close contact with the inner surfaces 16a and 16b by utilizing the elastic deformation of the flanges 222 and 223.

[0068] In this way, the gap 51 can be closed by a wedge effect before the resin material 300 flows into the gap 51. This separates the cavity 40 from the gap 51 and prevents the resin material 300 from unintentionally flowing into the gap 51. It should be noted that the mold gap 52 (see the Fig. 6) is narrow and has a high inflow resistance. For this reason, even if the resin material 300 flows into the mold cavity 52, the amount of resin material 300 is small.

[0069] Although not shown in detail, the resin material 300 cures after a predetermined period of time has elapsed in a state where the second mold 20 is at bottom dead center. After the resin material 300 has cured, the drive unit 3 moves the second mold 20 in the mold opening direction M1 to the retracted (upward) position. Next, the metal-resin composite structure 100 is removed from the first mold 10.

[0070] Since the resin material 300 is prevented from flowing into the gap 51, the manufacturing efficiency of the metal-resin composite structure 100 is increased. That is, because the amount of resin material 300 that cures in the receiving section 15 is small, the mold separation resistance can be reduced. After mold separation, the process of removing an unnecessary section of resin material 300 from the surface of the extruded material 200 is also simplified, and only minimal deburring is required. Since leakage of the composite material is prevented, an appropriate amount of resin material 300 in the cavity 40 can be easily ensured, and a defect-free product rate and yield are improved.

[0071] With renewed reference to the Fig. 1A and Fig. In Figure 1B, the cured resin material 300 has a plate section 301 projecting from the extruded material 200 on both sides in the width direction Y, and a projecting section 302 projecting from a central section in the width direction Y of the plate section 301. Profiles of the upper forming surface 43, the side forming surface 42, and the lower forming surface 41 (see the Fig. 6) are transferred to an upper surface, a side surface or a lower surface of plate section 301.

[0072] The projecting section 302 is provided on the projections 231 and 232, which contribute to closing the gap 51 (see the Fig. 6) The interior 220 is filled with the projecting section 302, which is brought into contact with a lower surface of the projecting sections 224 and 225. Since the resin material 300 is caulked and bonded to the extruded material 200, the bond strength of the resin material 300 with respect to the extruded material 200 is improved.

[0073] A section between a pair of flanges 222 and 223 is solidly formed with the resin material 300 and exhibits high strength. For this reason, flanges 222 and 223 can be made thin, thus improving flexibility. This allows for easy filling of the gap 51 (see the Fig. 7) as well as ensuring the strength of the metal-resin composite structure 100.

[0074] Furthermore, the upper surface of the flanges 222 and 223 is widened more than the plate thickness of the flanges 222 and 223 by integrating the projecting sections 223 and 224 and the protrusions 231 and 232. A contact surface between the extruded material 200 and the resin material 300 is ensured as far as possible. For this reason, not only the gap 51 (cf. the Fig. 7) at an upper end of the receiving section 15, such that an unnecessary section of the resin material 300 can be reduced, but also the bond strength of the resin material 300 in relation to the extruded material 200 can be maintained at a high value. (Second embodiment)

[0075] A second embodiment is described below, focusing on the differences from the embodiment described above.

[0076] With reference to the Fig. The extruded material 200 further comprises inclined outer surfaces 233 and 234, which are provided on the lower surface side of the protrusions 231 and 232. The inclined outer surfaces 233 and 234 connect a side surface of the protrusions 231 and 232 and an outer surface of the flanges 222 and 223 and are inclined downwards towards the interior in the lateral direction Y.

[0077] The relationship between the depth of the receiving section 15 and the height of the extruded material 200 is identical to that in the first embodiment. The width of the receiving section 15 is less than the maximum permissible width of the extruded material 200. This means that, in its design, the receiving section 15 can make contact with the extruded material 200, which has been formed within the dimensional tolerance.

[0078] The width of the receiving section 15 can be smaller than the minimum permissible width of the extruded material 200. In this case, the receiving section 15, during its design, makes contact with the extruded material 200, which has been formed within the dimensional tolerance. The width of the receiving section 15 can be set between the maximum permissible and the minimum permissible width of the extruded material 200, and may, for example, be identical to the reference width dimension. In a case where the width of the extruded material 200 is smaller than the reference dimension, the extruded material 200 is inserted into the receiving section 15 without contact with the receiving section 15, as is the case in the first embodiment.

[0079] With reference to the Fig. 9 In a case where the width of the extruded material 200 is greater than the width of the receiving section 15, when the extruded material 200 is received from above in the insertion position in the receiving section 15, substantially all of the extruded material 200 is inserted into the receiving section 15 without coming into contact with the receiving section 15. Immediately before the insertion is complete, the inclined outer surface 233 abuts a corner between the inner surface 16a of the receiving section 15 and the lower forming surface 41, and the inclined outer surface 234 abuts a corner between the inner surface 16b of the receiving section 15 and the lower forming surface 41.When a further downward force is applied to the extruded material 200, the protrusions 231 and 232 move inwards in the lateral direction Y by a wedge action, and the flanges 222 and 223 are elastically deformed inwards in the lateral direction Y. This allows the extruded material 200 to move downwards relative to the first die 10. The extruded material 200 moves downwards until the lower wall 201 rests on the inner lower surface 16c of the receiving section 15.

[0080] With reference to the Fig. 10. The deformation of the flanges 222 and 223 remains within an elastic range. Due to the elastic deformation, the flanges 222 and 223 exert a reaction force towards the outside in the lateral direction Y (the side approaching the inner surface of the receiving section 15) such that the original shape is restored (see arrow 5). The side surfaces of the protrusions 231 and 232 are pressed against the inner surfaces 16a and 16b of the receiving section 15 by this reaction force and are brought into close contact with these inner surfaces (see arrow 3).

[0081] According to the foregoing, as in the first embodiment, which is described in the Fig. 5 and Fig. As shown in Figure 6, a composite material of the resin material 300 is arranged in the first mold 10 and pressed at a high temperature and high pressure. In the present embodiment, the gap 51 is already filled before the resin material 300 is pressed into the mold. For this reason, it can be more reliably prevented that the resin material 300 flows into the gap 51. Furthermore, as in the first embodiment, the flanges 222 and 223 are formed based on the forming pressure exerted by the resin material 300 on the inclined inner surfaces 226 and 227 and an inner surface of the flanges 222 and 223 (see arrows 1 to 4 in the figure). Fig. 10), pressed outwards in the lateral direction Y. Therefore, the sealing capacity of the cavity 40 is further increased.

[0082] Since the protrusions 231 and 232 are in close contact with the inner surface 16 of the receiving section 15 due to a reaction force resulting from the elastic deformation of the flanges 222 and 223, the mold release resistance may be slightly higher than in the first embodiment, but curing of the resin material 300 in the gap 51 can be more reliably prevented. For this reason, the manufacturing efficiency of the metal-resin composite structure 100 is as high as that in the first embodiment. (Third embodiment)

[0083] A third embodiment is described below, focusing on the differences from the embodiment described above.

[0084] With reference to the Fig. In section 11, the extruded material 200 has a pair of projecting parts 235 and 236 that project outwards in the width direction Y from the tip sections of a pair of flanges 222 and 223, respectively. One pair of the projecting parts 235 and 236 is formed in a flat plate shape extending perpendicularly from the flanges 222 and 223. A pair of protrusions 231 and 232 is provided at the tip sections of one pair of the projecting parts 235 and 236, respectively. Each of the protrusions 231 and 232 projects downwards from a corresponding projecting part of the projecting parts 235 and 236. As described above, the protrusions 231 and 232 are provided on the outer surfaces of the flanges 222 and 223, with the projecting parts 235 and 236 positioned between them.

[0085] Each of the projecting parts 235 and 236 is integrated with a corresponding projecting section of the projecting sections 224 and 225 at a tip section of a corresponding flange of the flanges 222 and 223, so that a common upper surface is formed. It should be noted that in the present embodiment, the case is shown by way of example in which the projecting sections 224 and 225 do not have the inclined inner surfaces 226 and 227 (see the Fig. 4), however, the projecting sections 224 and 225 may have the inclined inner surfaces 226 and 227 as in the first embodiment.

[0086] With reference to the Fig. 12. The width of the receiving section 15 is greater than the maximum permissible dimension of a distance between the outer surfaces of the side walls 202 and 203. The depth of the receiving section 15 is less than the minimum permissible dimension of the length from a lower surface of the lower wall 201 to a lower surface of the projecting parts 235 and 236, and furthermore less than the minimum permissible dimension of the length from the lower surface of the lower wall 201 to a lower surface of a protrusion. As in the first embodiment, this allows the extruded material 200 to be fed downwards into the receiving section 15 without coming into contact with it, until the lower wall 201 rests on the inner lower surface 16c of the receiving section 15.

[0087] In a receiving state of the extruded material 200, an upper section of the extruded material 200 projects upwards with respect to the receiving section 15 or the lower forming surface 41. In particular, in the present embodiment, based on the dimensional relationship described above, not only the projecting parts 235 and 236, but also the protrusions 231 and 232 do not come into contact with the lower forming surface 41. The projecting parts 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 oriented towards the lower forming surface 41 with a small gap in the opening and closing directions. The composite material of the resin material 300 can be arranged on the projecting parts 235 and 236.

[0088] With reference to the Fig. 13 and Fig. When the second forming tool 20 moves downwards, the forming pressure is exerted on the upper surfaces 235a and 236a of the projecting parts 235 and 236 via the resin material 300 downwards (see arrow 6). The upper surfaces 235a and 236a act as pressure-absorbing surfaces that absorb the forming pressure. The projecting parts 235 and 236 are elastically deformed downwards, and the protrusions 231 and 232 come into close contact with an edge section of the receiving section 15 in the lower forming surface 41 (see arrow 3).

[0089] It should be noted that, as in the first and second embodiments, the forming pressure on the inner surfaces of the flanges 222 and 223 acts outwards in the lateral direction Y via the resin material 300 that has flowed into the interior 220 (see arrow 4). The flanges 222 and 223 are to be deformed outwards in the lateral direction Y about base end sections (near the sections where the upper wall 204 is provided) of the flanges 222 and 223, thereby moving the protrusions 231 and 232 downwards (see arrow 7). This process increases the degree of close contact between the protrusions 231 and 232 and an edge section of the receiving section 15 (see arrow 3).

[0090] The protrusions 231 and 232 are in close contact with the outside of the receiving section 15 instead of an inner surface of the receiving section 15, so that the cavity 40 is separated from the gap 51. Therefore, the resin material 300 is prevented from curing inside the receiving section 15 and outside the extruded material 200, and the mold release resistance is further reduced.

[0091] Although not shown in detail, the depth of the receiving section 15 can be greater than the minimum permissible dimension of the length from a lower surface of the lower wall 201 to the lower surfaces of the protrusions 231 and 232. In this case, even if the extruded material 200 has been formed within the dimensional tolerance, the length from the lower surface of the lower wall 201 to the lower surfaces of the protrusions 231 and 232 can be less than the depth of the receiving section 15. In such a case, the lower surfaces of the protrusions 231 and 232 abut the lower forming surface 41 before the lower wall 201 rests on the inner lower surface 16c. As the extruded material 200 continues to move downwards, the protruding parts 235 and 236 are elastically deformed.In a receiving state of the extruded material 200, the protrusions 231 and 232 are in close contact with an edge edge section of the receiving section 15. This separates the cavity 40 from the gap 51 before the resin material 300 is pressurized, and it can be more reliably prevented that the resin material 300 flows into the gap 51. (Fourth embodiment)

[0092] A fourth embodiment is described below, focusing on the differences from the embodiment described above.

[0093] With reference to the Fig. 15A and Fig. 15B comprises the metal-resin composite structure 100, structurally a frame section 101 with a rectangular frame shape and a lower plate section 102, which closes the lower surface side of the frame section 101, and is formed as a whole in a rectangular box shape. The resin material 300 forms the lower plate section 102 and also forms an inner surface of the frame section 101. A frame of the frame section 101 is formed by joining four of the extruded materials 200 in a rectangular frame shape.

[0094] Also with reference to the Fig. In the embodiment 16, the extruded material 200 comprises, as in the preceding embodiment, the lower wall 201, a pair of side walls 202 and 203, the upper wall 204, and the partition 205. However, the extruded material 200 does not include the flanges 221 and 222. The extruded material 200 as a whole has an L-shaped cross-section. The lower wall 201 and the partition 205 extend outwards in the lateral direction Y. The "outside" refers to the side opposite the inside of the frame section 101, which has a rectangular box shape. The extruded material 200 has an outer wall 206 that connects the extension sections of the lower wall 201 and the partition 205 in the vertical direction Z. The cavity 210 comprises a third chamber 213, which is surrounded by an extension section of the lower wall section 201 and the partition wall 205, a lower section of the side wall 203 and the outer wall 206.The resin material 300 is superimposed on an outer surface of the side wall 202 and forms an inner surface of the frame section 101. The extruded material 200 further comprises the protrusions 231 and 232. The protrusion 231 is provided on an upper section of the extruded material 200, and the protrusion 232 is provided on a lower section of the extruded material 200. However, the third chamber 213 and the outer wall 206 can be omitted, and the lower wall 201 and the partition 205 need not extend from the side wall 203.

[0095] In the present embodiment, the protrusion 231 is provided at a corner between the side wall 202 and the upper wall 204 and projects upward from the corner. The protrusion 232 is provided at a corner between the side wall 202 and the lower wall 201 and projects downward from the corner. The protrusions 231 and 232 have a wedge-shaped cross-section. The protrusion 231 has a pair of side surfaces and a top surface, and the side surface on the outside is inclined in the width direction. The protrusion 232 has a pair of side surfaces and a top surface, and the side surface on the outside is inclined in the width direction.

[0096] With reference to the Fig. In section 17, the forming tool 2 includes a third forming tool 30 in addition to the first forming tool 10 and the second forming tool 20. The shoulder section 12 is omitted from the first forming tool 10. An upper surface of the base section 11 forms the lower forming surface 41, a surface for arranging the extruded material 16d, and a lower fitting surface 17. The lower forming surface 41 is located in the center of the upper surface. The surface for arranging the extruded material 16d is formed in a rectangular frame shape that surrounds the lower forming surface 41. The lower fitting surface 17 is formed in a rectangular frame shape that surrounds the surface for arranging the extruded material 16d.

[0097] The second forming tool 20 comprises the main body section 21 and a forming section 22. The forming section 22 has a rectangular parallelepiped shape, smaller than the main body section 21, and projects downward from the main body section 21. A lower surface of the forming section 22 forms a first upper forming surface 44. Four sides of the forming section 22 form an inner forming surface 45. A step surface with a rectangular frame shape between the forming section 22 and the main body section 21 forms a second upper forming surface 46. Four side surfaces of the main body section 21 form the first upper fitting surface 24.

[0098] The third forming tool 30 is configured as a movable forming tool or an upper forming tool. The third forming tool 30 is configured in a rectangular frame shape and slides relative to the second forming tool 20. An outer edge section of a lower surface of the third forming tool 30 forms a lower mating surface 35. The third forming tool 30 has a recessed section 31 that extends upwards on the lower surface and forms a receiving section 15 together with the first forming tool 10. The recessed section 31 is configured in a mortar shape or an L-shape and gradually deepens from the outer edge section. The recessed section 31 is defined by a first inner surface 31a, a first inner lower surface 31b, a second inner surface 31c, and a second inner lower surface 31d.The first inner surface 31a extends upward from an inner edge of the lower fitting surface 35. The first inner lower surface 31b extends horizontally from an upper end of the first inner surface 31a to the inner surface of the third mold 30. The second inner surface 31c extends upward from an inner edge of the first inner lower surface 31b. The second inner lower surface 31d extends horizontally from an upper end of the second inner surface 31c to the inner surface of the third mold 30 and is continuous with an inner surface of the third mold 30. The inner surface of the third mold 30 forms a second upper fitting surface 34.

[0099] In the present embodiment, as described in the Fig. As shown in Figure 17, the extruded material 200 is arranged on the surface for arranging the extruded material 16d of the first forming tool 10 in a state where the second forming tool 20 and the third forming tool 30 are retracted upwards. Next, as shown in the Fig. As shown in Figure 18, the composite material of the resin material 300 is arranged on the lower forming surface 41, and the third forming tool 30 is moved downwards. This causes the extruded material 200 to be received in the receiving section 15, which is surrounded by the recessed section 31 and the surface for arranging the extruded material 16d. In this received state, the forming pressure is exerted on the extruded material 200 by the third forming tool 30 (see the white arrow). This brings the protrusion 231 into close contact with the second inner lower surface 31d of the third forming tool 30, and the protrusion 232 into close contact with the surface for arranging the extruded material 16d of the first forming tool 10 (see the white arrow).It should be noted that even if the extruded material 200 is bent or twisted, the extruded material 200 is elastically deformed and corrected by the forming pressure and the protrusions 231 and 232 are fully pressed in the longitudinal direction X against the forming tools 10 and 30.

[0100] When the extruded material 200 is held by the first forming tool 10 and the third forming tool 30, the second forming tool 20 is moved downwards to the bottom dead center, as shown in the Fig. 19 and Fig. 20 is shown. The second forming tool 20 is guided by the third forming tool 30 and slides downwards. The cavity 40 is defined by the lower forming surface 41, the first upper forming surface 43, an inner forming surface, a second upper forming surface, and an outer surface of the side wall 202 of the extruded material 200. Due to close contact of the protrusions 231 and 232, the cavity 40 is separated from the gap 51 between a surface of the extruded material 200 and an inner surface (the surface for arranging the extruded material 16d, the first inner surface 31a, the first inner lower surface 31b, the second inner surface 31c, and the second inner lower surface 31d) of the receiving section 15.

[0101] For this reason, in the present embodiment, it can also be prevented that the resin material 300 unintentionally flows into the gap 51 when the cavity 40 is filled with the resin material 300. After molding, as described in the Fig. As shown in Figure 21, the second forming tool 20 and the third forming tool 30 are withdrawn upwards. Even if the extruded material 200 has an outer wall and consequently a complex cross-sectional shape, the extruded material 200 can be easily separated from a forming tool. (Fifth embodiment)

[0102] A fifth embodiment is described below, focusing on the differences from the embodiment described above.

[0103] With reference to the Fig. In embodiment 21, the metal-resin composite structure 100 structurally comprises the frame section 101 and the lower plate section 102 as in the fourth embodiment, and a frame of the frame section 101 is configured such that four of the extruded materials 200 are joined in a rectangular frame shape. The resin material 300 forms not only the inner surfaces of the lower plate section 102 and the frame section 101, but also an upper surface of the frame section 101. Accordingly, the shapes of the second mold 20, the third mold 30, and the cavity 40 differ from those of the fourth embodiment.

[0104] With reference also to the Fig. In embodiment 22, the extruded material 200 is formed in an L-shape as in the fourth embodiment and has the protrusions 231 and 232. The protrusion 231 projects upward from a corner between the upper wall 204 and the side wall 203. The protrusion 232 projects inward in the width direction from a corner between the lower wall 201 and the side wall 202. A lower surface of the protrusion 232 is positioned slightly lower than a lower surface of the lower wall 201 (a surface to be positioned in the first die 10).

[0105] With reference to the Fig. 24 The second inner lower surface 31d of the third forming tool 30 has a width identical to the width of the upper wall 204 in the fourth embodiment, but in the present embodiment has a width corresponding to the thickness of the side wall 203. The extruded material 200 is arranged on the surface for arranging the extruded material 16d of the first forming tool 10 in a state in which the second forming tool 20 and the third forming tool 30 are retracted upwards.

[0106] Next, with reference to the Fig. 25 the third forming tool 30 moves downwards. This partially receives the extruded material 200 into the receiving section 15, which is surrounded by the surface for arranging the extruded material 16d and the recessed section 31. The upper wall 204 and the side wall 202 are free of the receiving section 15. The forming pressure of the third forming tool 30 brings the protrusion 231 into close contact with a second inner lower surface. The protrusion 232 is elastically deformed by the forming pressure and comes into close contact with the lower forming surface 41 or the surface for arranging the extruded material 16d. Next, the composite material of the resin material 300 is arranged on the lower forming surface 41.

[0107] Based on the foregoing, as stated in the Fig. 26 and Fig. As shown in Figure 27, the second forming tool 20 is moved to the bottom dead center. The cavity 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, an outer surface of the side wall 202 of the extruded material 200, and an outer surface of the upper wall 204 of the extruded material 200. Due to the close contact of the protrusions 231 and 232, the cavity 40 is separated from the gap 51 between a surface of the extruded material 200 and an inner surface (the surface for arranging the extruded material 16d, the first inner surface 31a, the first inner lower surface 31b, and the second inner surface 31c) of the receiving section 15.

[0108] For this reason, in the present embodiment, it can also be prevented that the resin material 300 unintentionally flows into the gap 51 when the cavity 40 is filled with the resin material 300. Furthermore, with reference to the Fig. 28 the metal-resin composite structure can be easily separated by a molding tool. (Sixth embodiment)

[0109] A sixth embodiment is described below, focusing on the differences from the embodiment described above.

[0110] With reference to the Fig. In 29, the metal-resin composite structure 100 structurally comprises the frame section 101 and the lower plate section 102 as in the fourth and fifth embodiments, and a frame of the frame section 101 is configured such that four of the extruded materials 200 are joined in a rectangular frame shape. The resin material 300 forms the lower plate section 102 and an inner surface of the frame section 101 and forms part of an upper surface of the frame section 101. Accordingly, the shapes of the second mold 20, the third mold 30, and the cavity 40 differ from those of the fourth embodiment.

[0111] With reference to the Fig. In the upper wall 204 of the extruded material 200, the outer side is higher in the width direction than the inner side. The upper wall 204 has a low section 204a extending inward in the width direction Y from an upper end section of the side wall 202, and a high section 204b extending outward in the width direction Y from an upper end section of the side wall 203. The extruded material 200 has a stepped section 204c connecting the low section 204a and the high section 204b in the height direction. The protrusion 232 is similar to that of the fifth embodiment. The protrusion 231 is provided in the stepped section 204c and projects outward in the width direction Y from a corner between the high section 204b and the stepped section 204c. This results in the protrusion 231 and the step section 204c being formed in a hook shape.

[0112] With reference to the Fig. The second inner lower surface 31d of the third mold 30 has a width equivalent to the width of the upper wall 204 in the fourth embodiment, but in the present embodiment has a width equal to the sum of the widths of the high section 204b and the protrusion 231. The extruded material 200 is arranged on the surface for arranging the extruded material 16d of the first mold 10 in a state in which the second mold 20 and the third mold 30 are retracted upwards.

[0113] Next, as it says in the Fig. As shown in Figure 32, the third forming tool 30 is moved downwards. This partially receives the extruded material 200 into the receiving section 15, which is surrounded by the surface for arranging the extruded material 16d and the recessed section 31. The lower section 204a of the upper wall 204 and the side wall 202 are exposed by the receiving section 15. The forming pressure of the third forming tool 30 brings the protrusion 231 into close contact with a second inner lower surface. The protrusion 231, which is shaped like a hook, is elastically deformed by the forming pressure and, due to its reaction force, comes into close contact with the third forming tool 30. The protrusion 232 is also in close contact with the lower forming surface 41 or the surface for arranging the extruded material 16d, in the same manner as in the fifth embodiment.Next, the composite material of the resin material 300 is arranged on the lower shaping surface 41.

[0114] Based on the foregoing, as stated in the Fig. 33 and Fig. As shown in Figure 34, the second forming tool 20 is moved to the bottom dead center. The cavity 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, an outer surface of the side wall 202 of the extruded material 200, and an outer surface of the lower section 204a of the upper wall 204 of the extruded material 200. Due to the close contact of the protrusions 231 and 232, the cavity 40 is separated from the gap 51 between a surface of the extruded material 200 and an inner surface (the surface for arranging the extruded material 16d, the first inner surface 31a, a first inner lower surface, and a second inner surface) of the receiving section 15.

[0115] For this reason, in the present embodiment, it can also be prevented that the resin material 300 unintentionally flows into the gap 51 when the cavity 40 is filled with the resin material 300. Furthermore, the metal-resin composite structure 100 can be described with reference to the Fig. 35 can be easily separated from a forming tool.

[0116] Although one embodiment of the present invention has been described above, the above structure can be modified, supplemented, and features can be omitted in a suitable manner within the scope of the present invention as defined in the claims. Reference symbol list 1 Manufacturing device 2 Forming tool 3 Drive unit 4 heating units 10 First forming tool 20 Second forming tool 30 Third forming tool 200 Extruded material 201 Lower wall 202, 203 side wall 204 Upper wall 205 Partition wall 210 cavity 211 First Chamber 212 Second Chamber 220 interior 221 Upper opening 222, 223 flange 224, 225 Prominent section 226, 227 Inclined inner surface 231, 232 Protrusion 233, 234 Inclined outer surface

Claims

[1] Method for producing a metal-resin composite structure (100) in which a resin material (300) is integrated with an extruded material (200) made of metal by compression molding, the method comprising: Preparing a forming tool (2) comprising a first forming tool (10) forming a receiving section (15) which receives at least a part of the extruded material (200) and a second forming tool (20) which is movable in an opening and closing direction with respect to the first forming tool (10); Receiving the extruded material (200) in the receiving section (15) and arranging the resin material (300) on the first mold tool (10); and Moving the second mold tool (20) in a mold tool closing direction to form a cavity (40) defined by a surface of the extruded material (200) and the mold tool (2), and filling the cavity (40) with the resin material (300) by applying pressure to the resin material (300), wherein the extruded material (200) has a protrusion (231, 232) that projects from the surface and approaches the receiving section (15) in a receiving state in which the extruded material (200) is received in the receiving section (15), and the protrusion (231, 232) is caused by the forming pressure exerted by the forming tool (2) on the extruded material (200) during filling to come into close contact with the receiving section (15) or an edge section thereof, and the cavity (40) is separated by a gap (51) between an inner surface of the receiving section (15) and the surface of the extruded material (200). [2] Method for producing a metal-resin composite structure (100) according to claim 1, wherein the forming pressure is exerted on the extruded material (200) via the resin material (300) during filling. [3] Method for producing a metal-resin composite structure (100) according to claim 2, wherein the extruded material (200) has a pair of flanges (222, 223) extending along the inner surface of the receiving section (15) in the receiving state, a pair of protrusions (231, 232) is provided on the pair of flanges (222, 223), the pair of flanges (222, 223) forms an interior space (220) between their inner surfaces and the interior space (220) forms part of the cavity (40), and the forming pressure during filling via the resin material (300) that has flowed into the interior (220) is exerted on the pair of flanges (222, 223), the pair of flanges (222, 223) is deformed to the inner surface of the receiving section (15) and the protrusion (231, 232) is brought into close contact with the receiving section (15) or the edge section thereof. [4] Method for producing a metal-resin composite structure (100) according to claim 3, wherein the protrusion (231, 232) is provided on an outer surface of the flange, and the protrusion (231, 232) comes into close contact with the inner surface of the receiving section (15) when filled with the resin material (300). [5] Method for producing a metal-resin composite structure (100) according to claim 4, wherein the extruded material (200) has an inclined inner surface (226, 227) provided on at least one of the tip sections of the pair of flanges (222, 223), and the inclined inner surface (226, 227) is inclined so that it is separated from the receiving section (15) to one side of the base end of the pair of flanges (222, 223) in the receiving state. [6] Method for producing a metal-resin composite structure (100) according to claim 5, wherein the extruded material (200) has a projecting section (224, 225) provided on at least one of the tip sections of the pair of flanges (222, 223) and projects further towards an inner side than an inner surface of the flange, and the inclined inner surface (226, 227) is formed on the projecting section (224, 225). [7] Method for producing a metal-resin composite structure (100) according to any one of claims 4 to 6, wherein the extruded material (200) has a pair of inclined outer surfaces (233, 234) provided on the side of a lower surface of at least one of the pair of protrusions (231, 232) and inclined such that they are separated from the receiving section (15) in a receiving direction of the extruded material (200) in the receiving section (15) in the receiving state, and When the extruded material (200) is received, the flange is deformed due to the contact of the inclined outer surface with the receiving section (15) to the inner side, and the protrusion (231, 232) comes into close contact with the inner surface of the receiving section (15) by an elastic force of the flange. [8] Method for producing a metal-resin composite structure (100) according to claim 3, wherein the extruded material (200) has a protruding part which extends from at least one of the tip sections of the pair of flanges (222, 223) to the outside of the flange and is exposed from the receiving section (15) in the receiving state, the protrusion (231, 232) is provided at a tip section of the projecting part, and the protrusion (231, 232) is brought into close contact with the edge section of the receiving section (15) when filled with the resin material (300). [9] Method for producing a metal-resin composite structure (100) according to claim 8, wherein the projecting part has a pressure-absorbing surface perpendicular to the opening and closing direction of the mold in the receiving state, and the protrusion (231, 232) is provided at a tip section of the projecting part and is directed towards the edge section in the opening and closing direction. [10] Method for producing a metal-resin composite structure (100) according to claim 1, wherein the forming tool (2) further comprises a third forming tool (30) which is movable in the opening and closing direction of the forming tool (2) with respect to the first forming tool (10) and forms the receiving section (15) together with the first forming tool (10), and the protrusion (231, 232) protrudes in the opening and closing direction in the receiving state and the third forming tool (30) comes into contact with the protrusion (231, 232) in such a way that the forming pressure is exerted by the third forming tool (30) on the extruded material (200). [11] Method for producing a metal-resin composite structure (100) according to claim 10, wherein a pair of protrusions (231, 232) is provided on both sides in the opening and closing direction of the extruded material (200), wherein one of the protrusions (231, 232) separates a section formed by the extruded material (200) and the first molding tool (10) from the gap (51) and the cavity (40), and the other of the protrusions (231, 232) separates a section formed by the extruded material (200) and the third molding tool (30) from the gap (51) and the cavity (40). [12] Method for producing a metal-resin composite structure (100) according to claim 11, wherein one of the protrusions (231, 232) projects in a direction that approaches the first forming tool (10) with respect to a surface of the extruded material (200) that is present on the first forming tool (10). [13] Method for producing a metal-resin composite structure (100) according to claim 11 or 12, wherein the other of the protrusions (231, 232) is provided in a step section (204c) of the extruded material (200) and has a hook shape, and the third forming tool (30) comes into contact with the other of the protrusions (231, 232) such that the forming pressure is exerted by the third forming tool (30) on the other of the protrusions (231, 232). [14] Device for producing a metal-resin composite structure (100) in which a resin material (300) has been integrated with an extruded material (200) made of metal by compression molding, the device comprising: a first forming tool (10) forming a receiving section (15) which partially receives the extruded material (200), and a second forming tool (20) which is movable relative to the first forming tool (10); and a movement mechanism that moves the second forming tool (20), wherein the extruded material (200) has a protrusion (231, 232) that projects from a surface of it and approaches the receiving section (15) in a receiving state in which the extruded material (200) is received in the receiving section (15), and When the second molding tool (20) is moved by the movement mechanism into a state in which the resin material (300) is arranged on the first molding tool (10), a cavity (40) defined by a surface of the extruded material (200) and the molding tool (2) is formed, the resin material (300) is pressurized so that it fills the cavity (40), the protrusion is brought into close contact with the receiving section (15) or an edge thereof by the forming pressure exerted on the extruded material (200) by the molding tool (2), and the cavity (40) is separated by a gap (51) between an inner surface of the receiving section (15) and the surface of the extruded material (200).

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