Mold for composite material and method for producing composite material

Abstract

A mold that molds a composite material including a metal member and a resin member bonded to the metal member, comprising: a mold body including an internal space including a first space into which the metal member is to be inserted, and a second space that is a cavity in which the resin member is to be molded; a surface of the metal member exposed to the second space when the metal member is inserted into the first space is a bonding surface; a plane that coincides with the position of the bonding surface when the metal member is not inserted into the first space is an imaginary plane; the first temperature sensor faces the first space, which is present in a projection range of the imaginary plane in a direction perpendicular to the imaginary plane;The second temperature sensor faces the second space present in the projection area of ​​the imaginary plane.;

Description

TECHNICAL FIELD

[0001] The present invention relates to molds for a composite material and methods for producing a composite material. STATE OF THE ART

[0002] Patent Document 1 cited below describes a method for manufacturing a composite material. This composite material is manufactured by joining a metal member and a resin member by injection molding. A mold used in this manufacturing method has a cavity into which the metal member is to be inserted and a cavity into which resin is to be injected. A temperature sensor is provided at the cavity into which the resin is to be injected. In this manufacturing method, parameters for an injection molding machine are adjusted based on the detection results from the temperature sensor. Patent Document 1 also discloses an estimation device that estimates the bonding strength between the metal member and the resin member. The bonding strength between the metal member and the resin member is estimated based on the surface roughness of the metal member.This estimator reduces manufacturing defects by estimating joint strength before the composite is manufactured. State of the art documentsPatent documents

[0003] Patent Document 1: Japanese Patent Application Laid-Open No. 2022-35285 (JP 2022-35285 A) SUMMARY OF THE INVENTIONProblem to be solved by the invention

[0004] It is believed that the bond strength between a metal member and a resin member in a composite material is also affected by temperature changes within a mold during molding, such as the temperature at the bonding point between the metal member and the resin member. The technique described in Patent Document 1 only measures the temperature at a position in the mold remote from the bonding point. Therefore, it is difficult to know the bonding point temperature.

[0005] An object of the present disclosure is to provide a mold for a composite material and a method for producing a composite material which make it possible to know the temperature of the junction between a metal member and a resin member. Means of solving the problem

[0006] (1) A mold for a composite material according to the present disclosure is a mold that molds a composite material including a metal member and a resin member bonded to the metal member. The mold includes: a mold body including a first space into which the metal member is to be inserted and a second space that is a cavity in which the resin member is to be molded; a first temperature sensor; and a second temperature sensor. A surface of the metal member exposed to the second space when the metal member is inserted into the first space is a bonding surface; a plane that coincides with a position of the bonding surface when the metal member is not inserted into the first space is an imaginary plane.The first temperature sensor faces the first space, which is present in a projection area of ​​the imaginary plane in a direction perpendicular to the imaginary plane. The second temperature sensor faces the second space, which is present in the projection area of ​​the imaginary plane.

[0007] (2) A method for manufacturing a composite material according to the present disclosure is a method for manufacturing a composite material including a metal member and a resin member bonded to the metal member using the mold according to (1). The method includes: a first step of measuring a temperature of the metal member introduced into the first space of the mold by the first temperature sensor; and a second step, after the first step, of measuring a temperature of the metal member introduced into the first space of the mold by the first temperature sensor and measuring a temperature of molten resin injected into the second space of the mold by the second temperature sensor. Effects of the invention

[0008] The present disclosure makes it possible to accurately know changes in temperature within a mold. BRIEF DESCRIPTION OF THE CHARACTERS [ Fig. 1] Fig. 1 is a longitudinal section of a composite material. [ Fig. 2] Fig. 2 is a longitudinal section of a mold. [ Fig. 3] Fig. 3 is a cross section of the mold. [ Fig. 4] Fig. 4 is a perspective view illustrating a projection range of a joining surface of a metal member. [ Fig. 5] Fig. 5 is a longitudinal section of the mold showing a molding portion of a joint of the composite material. [ Fig. 6] Fig. 6 is a sectional view along the line VI-VI in Fig. 5. [ Fig. 7A] Fig. 7A is a sectional view illustrating a procedure for forming the composite material. [ Fig. 7B] Fig. Figure 7B is a sectional view illustrating the procedure for forming the composite material. [ Fig. 7C] Fig. Figure 7C is a cross-sectional view illustrating the procedure for forming the composite material. [ Fig. 8] Fig. Figure 8 is a graph showing temperature changes of the metal element and a resin element. [ Fig. 9] Fig. 9 is a diagram illustrating transfer marks of protrusions of the mold. EMBODIMENTS FOR CARRYING OUT THE INVENTION <Overview of Embodiments of the Invention of the Present Disclosure>

[0009] An overview of embodiments of the invention of the present disclosure is listed and described below.

[0010] (1) A mold for a composite material according to the present disclosure is a mold that molds a composite material including a metal member and a resin member bonded to the metal member. The mold includes: a mold body including a first space into which the metal member is to be inserted and a second space that is a cavity in which the resin member is to be molded; a first temperature sensor; and a second temperature sensor. A surface of the metal member exposed to the second space when the metal member is inserted into the first space is a bonding surface; a plane that coincides with a position of the bonding surface when the metal member is not inserted into the first space is an imaginary plane.The first temperature sensor faces the first space, which is present in a projection area of ​​the imaginary plane in a direction perpendicular to the imaginary plane. The second temperature sensor faces the second space, which is present in the projection area of ​​the imaginary plane.

[0011] The mold with the above configuration can measure the temperature of the metal member and the temperature of the resin member at the junction between the metal member and the resin member. Therefore, with the mold with the above configuration, it is possible to know the temperature of the junction, for example, the temperature of the junction surface located at the boundary between the metal member and the resin member (such as heat transfer from the resin member to the metal member). The temperature of the junction affects the junction strength between the resin member and the metal member. For example, it is possible to estimate the junction strength between the metal member and the resin member using information indicating changes in these temperatures, or to control the temperature of the molded body, etc., while monitoring these temperatures to obtain the desired junction strength.By linking information obtained by quantifying measured temperatures with joint strength, this information can be used to design injection molding conditions for composite materials.

[0012] (2) According to a mold of (2), in the mold of (1), an inner surface of the molded body facing the imaginary plane in the second space has a plurality of projections and recesses. The projections and recesses are either projections or recesses, or both. With this configuration, the mold of (2) forms a plurality of transfer marks on the injected resin member. The plurality of transfer marks are a plurality of recesses or projections formed as a result of the transfer of the plurality of projections or recesses. Molten resin, which is melted by heating, is injected into the mold. The injected molten resin solidifies into the resin member when it is cooled within the mold. When the resin member is cooled after solidification, it shrinks considerably, especially in the portions other than the joint with the metal member.The relative positions and shapes of the plurality of transfer marks change as a result of this shrinkage. Changes in the relative positions and shapes of the protrusions and recesses of the mold caused by cooling are negligible compared to the changes in the relative positions and shapes of the plurality of transfer marks on the resin member. Therefore, shifts in the relative positions and shapes of the plurality of transfer marks on the resin member with respect to the relative positions and shapes of the protrusions and recesses of the mold relate to changes in the length and volume of the resin member caused by shrinkage due to cooling after solidification. The changes in the length and volume of the resin member due to shrinkage are related to residual stress (internal stress) generated in the resin member.Residual stress affects the bond strength between the metal element and the resin element. Therefore, knowing the changes in the length and volume of the resin element due to shrinkage, for example, allows estimating the bond strength between the metal element and the resin element and is also useful in designing injection conditions for composite materials.

[0013] (3) According to one of (3), in the mold of (1) or (2), an inner surface of the molded body extending in a direction intersecting the imaginary plane in the second space has a plurality of projections and recesses. With this configuration, the mold of (3) forms transfer marks on the molded resin member as in (2). Knowing displacements of the relative positions and shapes of the plurality of transfer marks with respect to the relative positions and shapes of the projections and recesses of the mold makes it possible to know changes in the length and volume of the resin member caused by shrinkage. Knowing the changes in the length and volume of the resin member due to shrinkage makes it possible to estimate the bonding strength between the metal member and the resin member and is also useful in designing injection conditions for composite materials.

[0014] (4) A method for manufacturing a composite material according to the present disclosure is a method for manufacturing a composite material including the metal member according to any one of (1) to (3) and a resin member bonded to the metal member, using the mold according to any one of claims 1 to 3. The method includes: a first step of measuring a temperature of the metal member introduced into the first space of the mold by the first temperature sensor; and a second step, after the first step, of measuring the temperature of the metal member introduced into the first space of the mold by the first temperature sensor and measuring a temperature of molten resin injected into the second space of the mold by the second temperature sensor.

[0015] In this manufacturing method, the temperature of the metal member can be measured by the first temperature sensor before and after the resin member is injected into the second space, and the temperatures of the injected molten resin and the resin component formed by solidifying the molten resin can be measured by the second temperature sensor. Knowing a change in the temperature of the metal member and a change in the temperature of the resin member makes it possible to estimate a change in the heat transferred from the molten resin or the resin member to the metal member. The change in the temperature of the metal member and the change in the temperature of the resin member can be related to the changes in the length and volume of the resin member due to shrinkage and the bonding strength with the metal member.

[0016] (5) According to a manufacturing method of (5), in the manufacturing method of (4), a temperature before the molten resin is injected into the second space is measured by the second temperature sensor in the first step. The manufacturing method of (5) makes it possible to know a change in temperature before and after the molten resin is injected into the second space. <Einzelheiten von Ausführungsformen der Erfindung der vorliegenden Offenbarung>

[0017] Embodiments of the present disclosure are described in detail below. Fig. 1 is a longitudinal section of a composite material. A composite material 1 of the present embodiment includes a metal member 2 and a resin member 3. The metal member 2 is, for example, aluminum or an aluminum alloy. However, the metal member 2 may be any metal that can be molded by injection molding, such as iron, stainless steel, or magnesium. The metal member 2 of the present embodiment is in the form of a long, narrow strip, and the metal member 2 is made of a plate material. The shape of the metal member 2 can be changed to any suitable shape.

[0018] The resin element 3 is formed from an engineering plastic such as PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), or PA (polyamide). However, the resin element 3 can be formed from any resin that can be injection-molded. The resin element 3 is in the shape of a long, narrow strip, and the resin element 3 is made of a sheet material. The shape of the resin element can be changed to any suitable shape.

[0019] The metal member 2 is essentially in the shape of a rectangular parallelepiped. The longest side of the metal member 2 is the width. The shortest side of the metal member 2 is the height. The side of the metal member 2 that is neither the width nor the height is the depth. The width direction is a longitudinal direction. The height direction is a height direction. The depth direction is a depth direction. A longitudinal end of the metal member 2 and a longitudinal end of the resin member 3 are connected to each other in an overlapping manner. The following is a section (section enclosed by a long dashed line, double short dashed line in Fig. 1) 5, where the metal member 2 and the resin member 3 overlap each other, is referred to as a "joint." In injection molding, the metal member 2 is used as an insert, and the resin member 3, which is a molded component formed as injected molten resin 3', solidifies, and the metal member 2 is joined into a single component.

[0020] Fig. 2 is a longitudinal section of the mold. Fig. 3 is a cross-sectional view of the mold. The mold 9 includes a mold body 10, temperature sensors 31, 32, and a pressure sensor 33. The mold body 10 includes a lower mold 11, an upper mold 12, and mold parts 13, 14. The lower mold 11 has a recessed portion 11a. After the mold part 13 and the mold part 14 are placed in the recessed portion 11a of the lower mold 11, the recessed portion 11a of the lower mold 11 is closed with the upper mold 12. An internal space 20 is thus formed within the mold body 10. The internal space 20 includes a first space 21 and a second space 22. The metal element 2 is placed in the first space 21. After the molded part 13, the molded part 14 and the metal element 2 are placed in the recessed portion 11a of the lower mold 11, the recessed portion 11a of the lower mold 11 is closed with the upper mold 12.The second space 22, which serves as a cavity, is thus formed within the mold body 10. The molten resin 3' (see . Fig. 7A) is injected into the second space 22. The molten resin 3' solidifies into the resin element 3 in the second space 22. As the molten resin 3' solidifies in the second space 22, it is bonded to the metal element 2. The resin element 3 and the metal element 2 are thus bonded into a single component, which is the composite material 1. The lower mold 11 or the upper mold 12 includes an injection channel 15 (see Fig. 3), through which the molten resin 3' is injected into the second space 22.

[0021] Ejector pins (pressing tools) 16 are placed in the lower mold 11. The ejector pins (pressing tools) 16 release the composite material 1 from the lower mold 11.

[0022] In Fig. 2 and Fig. 3, a portion surrounded by a long dashed double-short dashed line represents a projection area R obtained by projecting such a surface of the metal member 2 placed in the first space 21 as is exposed to the second space 22, that is, a bonding surface 2a of the metal member 2 with the resin member 3, in upward and downward directions (i.e., directions perpendicular to the bonding surface 2a). More specifically, as shown in Fig. 4, the projection area R is a three-dimensional area substantially in the shape of a prism or a rectangular parallelepiped. The projection area R includes an area (space) R2 obtained by projecting the joining surface 2a (portion hatched with dashed lines) of the metal member 2 upward (to one side in a perpendicular direction A), and an area (space) R1 obtained by projecting the joining surface 2a downward (to the other side in the perpendicular direction A). The projection area R can also be referred to as a spatial area in which the Fig. 1 shown connection point 5 is formed by molding. In Fig. 2 to Fig. 4 and Fig. 5 to Fig. 7, which are described below, the projection area R is shown slightly larger than its actual size to avoid overlapping lines for a better understanding of the projection area R.

[0023] Fig. Figure 5 is a longitudinal section of the mold showing a molding section of the composite material joint. As shown in Fig. 5, the mold 9 of the present embodiment includes the first temperature sensor 31 and the second temperature sensor 32. The surface of the metal member 2 exposed to the second space 22 when the metal member 2 is inserted into the first space 21 of the lower mold 11 is the joining surface 2a. A plane that coincides with the position of the joining surface 2a when the metal member 2 is not inserted into the first space 21 is an imaginary plane 2a. Therefore, a projection range R of the imaginary plane 2a coincides with the projection range R of the joining surface 2a. The first temperature sensor 31 is provided in the lower mold 11. The first temperature sensor 31 faces the first space 21 existing in the projection range R of the imaginary plane 2a.Specifically, the first temperature sensor 31 is provided on an inner surface 21a (surface forming the first space 21; specifically, the lower surface of the recessed portion 11a of the lower mold 11) of the mold body 10. The inner surface 21a contacts the opposite surface of the metal member 2 from the imaginary plane 2a. The first temperature sensor 31 faces the first space 21, which exists in the projection range R of the imaginary plane 2a in a direction perpendicular to the imaginary plane 2a. Therefore, the first temperature sensor 31 measures the temperature of the metal member 2. The temperature measured by the first temperature sensor 31 is substantially the temperature of the metal member 2.

[0024] The first temperature sensor 31 may be provided at any other position as long as it faces the first space 21 present in the projection range R of the imaginary plane 2a. For example, the first temperature sensor 31 may be provided on an inner surface 21b of the molded body 10 extending in a direction intersecting the imaginary plane 2a and forming the first space 21.

[0025] The second temperature sensor 32 is provided in the upper mold 12. The second temperature sensor 32 faces the second space 22 present in the projection range R of the imaginary plane 2a. Specifically, the second temperature sensor 32 is provided on an inner surface 22a (surface forming the second space 22; specifically, the lower surface of the upper mold 12) of the mold body 10. The inner surface 22a faces the imaginary plane 2a and forms the second space 22. The second temperature sensor 32 faces the second space 22 present in the projection range R of the imaginary plane 2a.Therefore, the second temperature sensor 32 measures the temperature of the second space 22, namely a cavity, before the molten resin 3' is injected, the temperature of the molten resin 3' while the molten resin 3' is injected, and the temperature of the resin member 3 formed as a result of the solidification of the molten resin 3'. The temperature measured by the second temperature sensor 32 is essentially any of the following temperatures: the temperature of the second space 22, the temperature of the molten resin 3', and the temperature of the resin member 3.

[0026] The second temperature sensor 32 may be provided at any other position as long as it faces the second space 22 present in the projection range R of the imaginary plane 2a. For example, the second temperature sensor 32 may be provided on an inner surface 22b of the molded body 10 extending in a direction intersecting the imaginary plane 2a and forming the second space 22.

[0027] As in Fig. 5, the mold 9 includes the pressure sensor 33. The pressure sensor 33 is formed at a position outside the projection range R of the imaginary plane 2a but close to the projection range R. Specifically, the pressure sensor 33 is provided on the inner surface 22a of the mold body 10 (lower surface of the upper mold 12) that forms the second space 22. The pressure sensor 33 measures the pressure of the molten resin 3' injected into the second space 22. This pressure is proportional to the filling density of the molten resin 3' in the second space 22. The pressure sensor 33, like the second temperature sensor 32, may face the second space 22 existing in the projection range R of the imaginary plane 2a.

[0028] Fig. 6 is a sectional view along the line VI-VI in Fig. 5. A plurality of projections and recesses 41 are provided on the inner surface 22a of the mold body 10 facing the joining surface 2a of the metal member 2, specifically, on the lower surface of the upper mold 12 located above the imaginary plane 2a. The projections and recesses 41 of the mold of the present embodiment are projections 41. The mold of the present embodiment has four projections 41. Each projection 41 has a cylindrical shape and protrudes from the lower surface of the upper mold 12. The positions and shape(s) of the four projections 41 are known in advance. The relative positional relationship between the four projections 41 and the shape(s) of the four projections 41 are determined in advance. In the mold body 10 of the present embodiment, the four projections 41 are arranged at positions corresponding to the four corners of a square (this arrangement is referred to as a square shape).Each projection 41 forms a recess as a transfer mark in the resin member 3 injected in the second space 22.

[0029] The four protrusions 41 may be arranged at positions corresponding to the four corners of a rectangle other than a square (rectangular shape), at positions corresponding to the four corners of a rhombus (rhombic shape), or at positions corresponding to the four corners of a parallelogram (parallelogrammatic shape). The number of protrusions 41 is two or more. The number of protrusions 41 is preferably three or more. Depending on the number of protrusions 41, the plurality of protrusions 41 may be arranged at positions corresponding to the three corners of a triangle (triangular shape), at positions corresponding to the five corners of a pentagon (pentagonal shape), or at other positions corresponding to the corners of a polygon (polygonal shape). Instead of the plurality of protrusions 41, a plurality of recesses may be provided on the inner surface 22a of the molded body 10.In this case, each recess forms a projection as a transfer mark in the resin member 3 injected in the second space 22.

[0030] As in Fig. As shown in Fig. 5, an adhesive 43 is provided on the bonding surface 2a of the metal member 2 placed in the first space 21. The resin member 3, which is injected into the second space 22, is bonded to the metal member 2 by the adhesive 43.

[0031] Fig. 7A to Fig. 7C are sectional views illustrating a method for molding the composite material. The method for molding the composite material 1 will be described with reference to Fig. 7A to Fig. 7C described.

[0032] Fig. 7A shows a first state. The first state is a state in which the two mold parts 13, 14 have been placed in the recessed portion 11a of the lower mold 11 and the metal element 2 has been introduced into the first space 21. The first state is a state in which the molten resin 3' is injected into the second space 22.

[0033] Fig. 7B shows a second state. The second state is a state in which the molten resin 3' has been injected into the second space 22. In the second state, pressure is applied in the inner space 20, and the molten resin 3' conforms to the engraved pattern of the first space 21 (cavity) of the molded body 10. Afterward, the molten resin 3' is cooled and thus solidifies into the resin member 3. When the molten resin 3' solidifies, the metal member 2 and the resin member 3 are bonded to form the composite material 1.During the steps up to this point, the first temperature sensor 31 measures the temperature of the metal member 2, the second temperature sensor 32 measures the temperature of the second space 22, which is a cavity before the molten resin 3' is injected, the temperature of the molten resin 3' while the molten resin 3' is injected, and the temperature of the resin member 3 formed as a result of the solidification of the molten resin 3', and the pressure sensor 33 measures the pressure of the molten resin 3' injected into the second space 22.

[0034] Fig. Figure 7C shows a third state. After the composite material 1 has been molded, the upper mold 12 of the molded body 10 is removed from the lower mold 11, and the molded composite material 1, together with the two molded parts 13, 14, is removed from the recessed portion 11a of the lower mold 11 by the ejector pins 16.

[0035] When the composite material 1 is formed through the above steps, the resin member 3 shrinks when cooled in the cooling step. A portion of the resin member 3 is bonded to the bonding surface 2a of the metal member 2. The amount of shrinkage of the resin member 3 is small near the bonding surface 2a and increases with increasing distance from the bonding surface 2a. Therefore, a portion of the resin member 3 located near the bonding surface 2a tends to be subjected to internal stress (residual stress) because shrinkage is restricted. This residual stress affects the bonding strength between the metal member 2 and the resin member 3 at the bonding surface 2a. Therefore, knowing the amount of shrinkage of the resin member 3 is useful in estimating and managing the bonding strength.

[0036] Fig. Figure 8 is a graph showing changes in the temperature of the metal element and the resin element. For example, the temperature of the metal element 2 measured by the first temperature sensor 31 and the temperature of the resin element 3 measured by the second temperature sensor 32 change in a manner shown in Fig. 8. In a state immediately before the molten resin 3' is injected into the second space 22, a measured value of the first temperature sensor 31 and a measured value of the second temperature sensor 32 are both approximately equal to or close to the temperature To of the molded body 10. The temperature of the molded body 10 is constantly controlled by a control device not shown.

[0037] When the molten resin 3' is injected into the second space 22, the measured value of the second temperature sensor 32 quickly rises to the temperature Tr of the molten resin 3' when the second temperature sensor 32 comes into contact with the molten resin 3'. The heat of the molten resin 3' is gradually transferred to the metal member 2, causing the temperature of the metal member 2 to rise. As the temperature of the metal member 2 rises, the measured value of the first temperature sensor 31 gradually increases. The heat of the molten resin 3' is absorbed by the mold 9 and the metal member 2. Therefore, the measured value of the second temperature sensor 32 gradually decreases. After the measured value of the first temperature sensor 31 reaches its peak value Tm, the measured value of the first temperature sensor 31 and the measured value of the second temperature sensor 32 converge to the same temperature, and both gradually decrease.

[0038] As described above, with the mold 9 of the present embodiment, it is possible to know changes in the temperature of the joint 5 of the composite material 1 because the first temperature sensor 31 measures the temperature of the metal member 2 and the second temperature sensor 32 measures the temperature of the resin member 3 (molten resin 3'). Specifically, with the mold 9 of the present embodiment, it is possible to know the temperature near the joint surface 2a located at the boundary between the metal member 2 and the resin member 3. For example, it is possible to know the heat transfer from the resin member 3 to the metal member 2 through the joint surface 2a.

[0039] Changes in the temperature of the joint 5 affect the bonding strength between the metal member 2 and the resin member 3. For example, if the temperature of the joint 5 is too low or too high, the bonding strength of the joint 5 may decrease. Using the mold 9 of the present embodiment makes it possible to know changes in the temperature of the joint 5 during the production of the composite material 1. This makes it possible to relate the temperature changes to the bonding strength between the metal member 2 and the resin member 3, optimize the mold temperature based on the data obtained by bonding, estimate the bonding strength based on the temperature changes, and control the temperature of the molded body 10 while monitoring the temperature changes.With the mold 9 of the present embodiment, it is possible to achieve adequate joint strength by using data on the temperature changes of the joint 5. It is also possible to reduce variations in the quality of the composite material 1 by monitoring the temperature changes of the joint 5.

[0040] Fig. Fig. 9 is a diagram illustrating transfer marks from the protrusions of the mold. There are four depressions 3a on the surface of the resin member 3 of the injected composite material 1 as transfer marks from the protrusions 41 (see Fig. 6) on the molded body 10. After injection molding, the resin member 3 of the composite material 1 shrinks when it is cooled. When the resin member 3 does not shrink, the four recesses 3a transferred to the resin member 3 are arranged in a square shape like the arrangement of the projections 41 (shown by long, double-short dashed lines in Fig.9). As the resin member 3 shrinks, the relative positions of the four recesses 3a change. For example, the distances L1 to L4 between adjacent recesses 3a, the distances L5, L6 between diagonally positioned recesses 3a, the angle θ between two diagonals, etc., change. The shape of the recesses 3a also changes with respect to the shape of the protrusions 41. Therefore, measuring these values ​​L1 to L6, θ and analyzing changes in the position of the recesses 3a and the shapes of the recesses 3a makes it possible to know changes in shrinkage (amount of shrinkage, shrinkage direction, etc.) of the resin member 3. Parameters other than the above distances and angles of the four recesses 3a can also be used to know changes in shrinkage of the resin member 3.

[0041] The changes in shrinkage of the resin element 3 are related to the filling density of the molten resin 3' in the second space 22 of the molded body 10. The higher the filling density of the molten resin 3', the smaller the shrinkage of the resin element 3. Based on the fact that the filling density of the molten resin 3' is proportional to the pressure in the second space 22, changes in pressure obtained from the measured value of the pressure sensor 33 can be used to estimate the filling density of the molten resin 3'. Therefore, the changes in pressure obtained from the measured value of the pressure sensor 33 can be used to know the changes in shrinkage of the resin element 3.

[0042] Furthermore, as described above, a portion of the resin member 3 located near the joining surface 2a of the metal member 2 shrinks slightly due to the shape constraint of the resin member 3. However, the constraint decreases as the distance of the resin member 3 from the joining surface 2a increases. Therefore, another portion of the resin member 3 located far from the joining surface 2a shrinks significantly. Therefore, the portion of the resin member 3 located near the joining surface 2a is pulled by the joining surface 2a and tends to be subjected to residual stress such as tensile stress. This residual stress correlates with changes in the shrinkage of the resin member 3 and also affects the joining strength between the metal member 2 and the resin member 3.

[0043] Therefore, with injection molding using the mold 9 of the present embodiment, it is possible to know changes in shrinkage of the resin member 3 by using the relative positional relationship between the four recesses 3a formed in the resin member 3, the shapes of the recesses 3a, the measured value of the pressure sensor 33, etc., and to estimate the bonding strength between the metal member 2 and the resin member 3 from the changes in shrinkage. Controlling the filling rate and filling amount of the molten resin 3' while monitoring the pressure of the molten resin 3' enables the composite material 1, which is an injection-molded product, to have appropriate bonding strength and reduces fluctuations in quality.

[0044] By accumulating data on the measured values ​​of the temperature sensors 31, 32, the measured values ​​of the pressure sensor 33, and features (e.g., integral values, maximum values, minimum values, slopes of graphs, etc.) calculated using these measured values, and analyzing the relationship between the data and the bonding strength of the composite material 1 obtained by a tensile test, etc. after injection molding, or by analyzing the adhesion mechanism from the data, the analysis results can be reflected in a model-based development for manufacturing and designing the composite material 1. [More]

[0045] The above embodiment is illustrative and not restrictive in all respects. The scope of the present invention is set forth in the claims and is intended to include all modifications within the meaning and scope of the claims.

[0046] For example, the joining surface 2a of the metal element 2 need not be a flat surface and may be a curved surface or a bent surface. In any case, the temperature sensors 31, 32 are arranged to face the first space 21 or the second space 22 present in the projection area R in the direction perpendicular to the joining surface 2a or an imaginary plane corresponding to the joining surface 2a. List of reference symbols

[0047] 1 ... composite material, 2 ... metal element, 2a ... joining surface, 3 ... resin element, 9 ... mold, 10 ... mold body, 20 ... interior space, 21 ... first space, 22 ... second space, 31 ... first temperature sensor, 32 ... second temperature sensor, 41 ... projection, A ... normal direction, R ... projection area QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] JP 2022-35285

[0003] JP 2022-35285 A

[0003]

Claims

[1] A mold for a composite material, the mold being configured to mold the composite material including a metal member and a resin member bonded to the metal member, the mold comprising: a molded body including an interior space, the interior space having a first space into which the metal member is to be inserted and a second space which is a cavity in which the resin member is to be molded; a first temperature sensor; and a second temperature sensor, where: a surface of the metal member exposed to the second space when the metal member is inserted into the first space is a bonding surface; a plane corresponding to a position of the joining surface when the metal element is not inserted into the first space is an imaginary plane; the first temperature sensor faces the first space present in a projection area of ​​the imaginary plane in a direction perpendicular to the imaginary plane; and the second temperature sensor faces the second space present in the projection area of ​​the imaginary plane. [2] The mold for the composite material according to claim 1, wherein an inner surface of the molded body facing the imaginary plane in the second space has a plurality of projections and recesses, and the projections and recesses are one or both of projections and recesses. [3] The mold for the composite material according to claim 1, wherein an inner surface of the molded body extending in a direction intersecting the imaginary plane in the second space has a plurality of projections and recesses. [4] A method for producing a composite material including a metal member and a resin member bonded to the metal member using the mold according to any one of claims 1 to 3, the method comprising: a first step of measuring a temperature of the metal element introduced into the first space of the mold by the first temperature sensor; and a second step, after the first step, of measuring the temperature of the metal member introduced into the first space of the mold by the first temperature sensor and measuring a temperature of molten resin injected into the second space of the mold by the second temperature sensor. [5] A method for producing the composite material according to claim 4, wherein in the first step, a temperature before the molten resin is injected into the second space is measured by the second temperature sensor.

Images