Molding tool, and manufacturing method of composite material

Abstract

To provide a technique in which the state of an adhesive on the surface of a metal member arranged in a metal mold can be acquired.SOLUTION: A molding tool 10 comprises: a metal mold 12 having an inner space S including a first space s1 into which a metal member 2 is inserted, a second space s2 that is a mold cavity in which a resin member 4 is molded by injecting a molten resin, and an opening s3 that connects the first space s1 and the second space s2; a light projection unit 14 for emitting an infrared light toward inside of the second space s2; and a light reception unit 16 that receives the reflected light of the infrared light and introduces the reflected light to a spectrometer 24. The metal member 2 has a joint surface 2a that is exposed to the second space s2 from the opening s3 when the metal member 2 is inserted into the first space s1. The light projection unit 14 emits the infrared light toward a virtual surface F corresponding to the opening s3, the virtual surface F being included in an inner surface s2a defining the second space s2. The light reception unit 16 includes a light-receiving window 16 which is arranged on the opposite surface 12a11 facing the virtual surface F to transmit the reflected light.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a molding die and a method for manufacturing a composite material.

Background Art

[0002] Patent Document 1 discloses a technique for molding a composite material having a metal member and a resin member joined to each other. This composite material is manufactured by applying an adhesive to the surface of a metal member such as an aluminum alloy, placing this metal member in a mold, and injection-molding a resin member onto the portion where the adhesive is applied.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The above adhesive contains a main agent and a curing agent. This adhesive cures by heating. After the adhesive is applied to the metal member and cured to form a coating film so as to have a certain reactivity, the adhesive is heated and further cured during injection molding to form an adhesive layer. The adhesive layer is interposed between the metal member and the resin member and joins the two.

[0005] During injection molding, the metal member is placed in a heated mold. At this time, the adhesive is heated by the mold. Then, the molten resin is injected into the mold, and the adhesive is further heated by the injected molten resin.

[0006] Here, if the amount of heat applied to the adhesive until the molten resin is injected into the mold is not sufficient, the adhesive may not be sufficiently cured by the heating by the injected molten resin. Conversely, when the molten resin is injected into the mold, if the coated adhesive is heated more than necessary and the curing of the adhesive progresses too far, the strength of the composite material may decrease. Therefore, it is necessary to inject the molten resin into the mold when the state of the adhesive is appropriate. Thus, a method for obtaining the state of the adhesive on the surface of the metal member disposed in the mold is desired.

Means for Solving the Problems

[0007] The molding die according to the embodiment is a molding die for molding a composite material having a metal member and a resin member joined to each other. This molding die has a mold body having an internal space including a first space into which the metal member is inserted, a second space which is a cavity in which the resin member is molded by injection of molten resin, and an opening connecting the first space and the second space, a light projecting portion that emits infrared light into the second space, and a light receiving portion that receives the reflected light of the infrared light and guides the reflected light to a spectroscope. The metal member has a joint surface that is exposed from the opening to the second space when the metal member is inserted into the first space. The light projecting portion emits the infrared light toward a virtual surface included in the inner surface defining the second space and corresponding to the opening. The light receiving portion has a light receiving window provided on an opposing surface included in the inner surface and opposing the virtual surface, and transmitting the reflected light.

Effects of the Invention

[0008] According to the present disclosure, the state of the adhesive on the surface of the metal member disposed in the mold can be obtained.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7A

Figure 7B

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0010] First, the content of the embodiment will be listed and described. [Summary of the Embodiment] (1) The molding die according to the embodiment is a molding die for molding a composite material having a metal member and a resin member joined to each other. This molding die includes a die body having an internal space including a first space into which the metal member is inserted, a second space which is a cavity in which the resin member is molded by injection of molten resin, and an opening connecting the first space and the second space, a light projecting unit that emits infrared light into the second space, and a light receiving unit that receives the reflected light of the infrared light and guides the reflected light to a spectroscope. The metal member has a joint surface that is exposed from the opening to the second space when the metal member is inserted into the first space. The light projecting unit emits the infrared light toward a virtual surface included in an inner surface defining the second space and corresponding to the opening. The light receiving unit is provided on an opposing surface included in the inner surface and opposing the virtual surface, and has a light receiving window that transmits the reflected light.

[0011] According to the above configuration, since infrared light is emitted toward the virtual plane corresponding to the opening, the adhesive applied to the joint surface of the metal member inserted into the first space can be irradiated with infrared light. Further, since a light receiving window that transmits the reflected light is provided on the opposing surface facing the virtual plane, the light receiving unit can take in the reflected light of the infrared light irradiated to the adhesive through the light receiving window and guide the reflected light to the spectroscope. Thereby, by spectroscopically analyzing the reflected light, the components of the curing agent contained in the adhesive can be quantitatively analyzed, and the state of the adhesive on the surface of the metal member disposed in the mold can be obtained. As a result, when the state of the adhesive is appropriate, the injection of the molten resin into the second space can be started, and a composite material having stable strength can be obtained.

[0012] (2) In the above-described molding die, the light receiving unit may further include an optical fiber that extends from the light receiving window to the outside of the die body and guides the reflected light that has passed through the light receiving window to the spectroscope. In this case, the reflected light can be guided to a spectroscope disposed outside the molding die.

[0013] (3) In the above-described molding die, when the light projecting unit has a light projecting window provided on the opposing surface and capable of transmitting the infrared light, the infrared light is preferably emitted from the light projecting window toward the virtual plane. In this case, the infrared light can be emitted so that the infrared light is effectively reflected toward the light receiving window on the opposing surface.

[0014] (4) Further, from another perspective, an embodiment is a method for manufacturing the composite material using the mold described in (1) above. This manufacturing method includes applying an adhesive containing a main agent and a curing agent to the bonding surface of the metal member, heating the metal member to form a coating film of the adhesive, inserting the metal member into the first space of the heated mold body to heat the metal member, irradiating the infrared light emitted from the light projecting unit onto the adhesive on the bonding surface, causing the spectrometer to acquire a value indicating the amount of substance of the curing agent based on the reflected light guided to the spectrometer by the light receiving unit, and starting the injection of the molten resin into the second space when the value indicating the amount of substance is within a predetermined numerical range.

[0015] According to the above configuration, by heating the metal member with the mold, the reaction between the main agent and the curing agent proceeds, and the amount of substance of the curing agent decreases. During this time, the adhesive is irradiated with infrared light, and the amount of substance of the curing agent can be obtained based on the reflected light. In this way, while promoting the reaction of the adhesive on the surface of the metal member 2 disposed in the mold body 12, the state of the adhesive can be obtained. Therefore, if a predetermined numerical range is preset to a suitable value as the timing for injecting the molten resin into the second space, the injection of the molten resin can be started when the amount of substance of the curing agent in the adhesive in the mold body is appropriate. As a result, a composite material having stable strength can be obtained.

[0016] [Details of the Embodiment] Hereinafter, preferred embodiments will be described with reference to the drawings. [Regarding the Composite Material] FIG. 1 is a perspective view showing an example of a composite material manufactured by the manufacturing method according to the present embodiment. The composite material 1 includes a metal member 2, a resin member 4, and an adhesive layer 6. The metal member 2 is a rectangular plate-shaped member. As the material of the metal member 2, an aluminum alloy, a magnesium alloy, carbon steel for mechanical structures, alloy steel for mechanical structures, etc. are used. The resin member 4 is a rectangular plate-shaped member. As the resin that is the material of the resin member 4, engineering plastics are used. As the engineering plastics, polyamide, polybutylene terephthalate, polyphenylene sulfide, etc. are used. As the polyamide, polyamide 66, polyamide 11, polyamide 6T / 6I, polyamide 6, polyamide 46, polyamide 9T, etc. are used. The resin member 4 may further contain reinforcing fibers, additives, lubricants, etc. As the reinforcing fibers, glass fibers, carbon fibers, aramid fibers, etc. are used.

[0017] The adhesive layer 6 is interposed between the metal member 2 and the resin member 4. The metal member 2 and the resin member 4 are joined to each other via the adhesive layer 6.

[0018] The adhesive layer 6 is a cured adhesive layer obtained by curing a curable adhesive containing a liquid main agent and a curing agent. The main agent of this adhesive is, for example, an organic compound having two or more hydroxyl groups. The curing agent of the adhesive contains, for example, an isocyanate compound. The isocyanate compound has an isocyanate group.

[0019] The ratio of the main agent to the curing agent is determined by the amount of hydroxyl groups contained in the main agent and the amount of isocyanate groups contained in the curing agent. When the above main agent and curing agent are mixed, the hydroxyl group and the isocyanate group react to obtain a urethane resin which is a cured product. That is, the adhesive layer 6 is a cured layer containing a urethane resin.

[0020] The adhesive is applied to the joint surface 2a of the metal member 2. The joint surface 2a is a surface that faces a part of the surface 4a of the resin member 4 as shown in FIG. 1. The joint surface 2a is a surface that is joined to a part of the surface 4a. After an adhesive is applied to the joint surface 2a of the metal member 2, the resin member 4 is injection-molded so as to face the joint surface 2a. The adhesive is heated between the time it is applied to the joint surface 2a and the time the resin member 4 is injection-molded, and cures with a certain degree of reactivity. The adhesive is further cured by the resin member 4 to form the adhesive layer 6.

[0021] 〔Regarding the molding die〕 FIG. 2 is a cross-sectional view showing an example of the molding die used for manufacturing the composite material 1. FIG. 3 is a cross-sectional view taken along the arrow III-III in FIG. 4. FIG. 4 is a cross-sectional view taken along the arrow IV-IV in FIG. 3. Note that FIG. 2 shows a cross-sectional view taken along the arrow II-II in FIG. 3. The molding die 10 includes a die body 12, a light projecting part 14, and a light receiving part 16. Further, a spectroscopic analyzer 17 is connected to the molding die 10. The spectroscopic analyzer 17 is disposed outside the molding die 10.

[0022] The die body 12 has a first die part 12a and a second die part 12b. An internal space S is provided between the first die part 12a and the second die part 12b. The internal space S is a space for molding the composite material 1. The internal space S includes a first space s1 and a second space s2.

[0023] The internal space S is formed by butting a dividing surface 12a1 and a dividing surface 12b1. The dividing surface 12b1 of the second die part 12b has a rectangular recess that becomes the first space s1. Further, the dividing surface 12a1 of the first die part 12a has a rectangular recess that becomes the second space s2. The recess that becomes the first space s1 and the recess that becomes the second space s2 are offset along the longitudinal direction. Thus, the dividing surface 12a1 closes a part of the recess that becomes the first space s1. The dividing surface 12b1 closes a part of the recess that becomes the second space s2. The overlapping part of the recess that becomes the first space s1 and the recess that becomes the second space s2 becomes an opening s3 (described later).

[0024] The first space s1 is a space into which the metal member 2 is inserted. Thus, the first space s1 has a rectangular shape corresponding to the metal member 2. The second space s2 is a cavity in which the resin member 4 is injection-molded. Therefore, the second space s2 has a rectangular shape corresponding to the resin member 4. A supply path (not shown) for injecting molten resin into the second space s2 is provided in the mold body 12.

[0025] The first space s1 and the second space s2 are connected via the opening s3. The opening s3 opens rectangularly into the first space s1 as viewed from the second space s2. Also, the opening s3 opens rectangularly into the second space s2 as viewed from the first space s1. The opening s3 coincides with the joint surface 2a when the metal member 2 is inserted into the first space s1. Therefore, the joint surface 2a is exposed from the opening s3 into the second space s2 when the metal member 2 is inserted into the first space s1.

[0026] The light projecting unit 14 has a function of emitting infrared light into the second space s2. As shown in FIGS. 3 and 4, the light projecting unit 14 includes a light projecting window 18 and a light projecting side optical fiber 20. As shown in FIG. 4, the spectroscopic analyzer 17 includes an infrared light source 22. The infrared light source 22 outputs infrared light (interference wave) used for infrared spectroscopic analysis and supplies it to the light projecting side optical fiber 20. The infrared light emitted by the spectroscopic analyzer 17 is supplied to the light projecting unit 14 via the light projecting side optical fiber 20.

[0027] The light projecting side optical fiber 20 is inserted into the passage 12a2. The passage 12a2 is a hole that communicates the bottom surface 12a12 and the side surface 12a3 of the first mold part 12a. The bottom surface 12a12 is the bottom surface of the recess of the split surface 12a1. The opening on the split surface 12a1 side of the passage 12a2 is provided at the position of the light projecting window 18. One end of the light projecting side optical fiber 20 is connected to the infrared light source 22. The other end of the light projecting side optical fiber 20 is connected to the light projecting window 18. The light projecting side optical fiber 20 connects the external infrared light source 22 and the light projecting window 18 and guides the infrared light supplied from the infrared light source 22 to the light projecting window 18.

[0028] The light projection window 18 is provided on the opposing surface 12a11. The opposing surface 12a11 is a portion of the inner surface s2a that defines the second space s2 and faces the virtual surface F. The bottom surface 12a12 is a part of the inner surface s2a. Also, the opposing surface 12a11 is a part of the bottom surface 12a12. The virtual surface F is a surface included in the inner surface s2a and corresponds to the opening s3.

[0029] As shown in FIG. 3, the light projection window 18 has a window lid 18a and a window frame 18b. The window lid 18a closes the opening on the side of the dividing surface 12a1 of the passage 12a2. The window lid 18a is formed of a material that can transmit infrared light. Examples of materials that can transmit infrared light include sapphire glass. The window frame 18b holds the window lid 18a. The window frame 18b is recessed with respect to the opposing surface 12a11. As a result, the outer surface 18a1 of the window lid 18a is flush with the opposing surface 12a11.

[0030] The other end of the light projection side optical fiber 20 is fixed to the window lid 18a. Infrared light from the infrared light source 22 is emitted from the other end of the light projection side optical fiber 20. The other end of the light projection side optical fiber 20 is fixed to the window lid 18a such that the optical axis of the infrared light emitted from the light projection unit 14 is orthogonal to the window lid 18a. As a result, the light projection unit 14 emits infrared light toward the virtual surface F. The light projection unit 14 emits infrared light along a direction orthogonal to the virtual surface F.

[0031] The light receiving unit 16 has a function of receiving the reflected light of the infrared light emitted from the light projection unit 14 and guiding the reflected light to the spectroscopic analyzer 17. As shown in FIGS. 2 and 3, the light receiving unit 16 includes a light receiving window 28 and a light receiving side optical fiber 30. The light receiving window 28 is provided on the opposing surface 12a11. The light receiving window 28 is provided adjacent to the light projection window 18. The light receiving window 28 has a window lid 28a and a window frame 28b.

[0032] The window lid 28a closes the opening on the split surface 12a1 side of the passage 12a4. The window lid 28a is formed of a material capable of transmitting infrared light. The passage 12a4 is a hole that communicates the bottom surface 12a12 and the side surface 12a3. The passage 12a4 is provided adjacent to the passage 12a2. A light receiving side optical fiber 30 is inserted into the passage 12a4. The window frame 28b holds the window lid 28a. The window frame 28b is recessed with respect to the opposing surface 12a11. Thereby, the outer surface 28a1 of the window lid 28a is flush with the opposing surface 12a11.

[0033] The light receiving side optical fiber 30 connects the external spectroscopic analyzer 17 and the light receiving window 28. One end of the light receiving side optical fiber 30 is connected to the spectroscope 24 of the spectroscopic analyzer 17. The other end of the light receiving side optical fiber 30 is fixed to the light receiving window 28 so that the infrared light transmitted through the light receiving window 28 can be guided to the spectroscope 24. More specifically, the other end of the light receiving side optical fiber 30 is fixed so that the light receiving axis when the light receiving unit 16 receives infrared light is orthogonal to the window lid 28a.

[0034] The spectroscopic analyzer 17 is a Fourier Transform Infrared Spectroscopy (FT-IR) device or a Non-Dispersive Infrared Spectroscopy (ND-IR) device. The spectroscopic analyzer 17 has a function of outputting infrared light, which is an interference wave, from the infrared light source 22 and performing quantitative analysis on the components of the curing agent based on the reflected light of this infrared light. The spectroscope 24 spectroscopes the reflected light guided by the light receiving unit 16. The spectroscopic analyzer 17 can obtain a value A indicating the amount of substance of the curing agent by spectroscopically analyzing the reflected light. The value A indicating the amount of substance of the curing agent may be the absorbance at the wave number (wavelength) corresponding to the components of the curing agent, or the amount of substance obtained from the absorbance.

[0035] Regarding the method for manufacturing the composite material FIG. 5 is a flowchart showing an example of a method for manufacturing a composite material. As shown in FIG. 5, when manufacturing the composite material 1, first, the surface of the metal member 2 is cleaned (step S1 in FIG. 5). Next, an adhesive containing a main agent and a curing agent is applied to the bonding surface 2a of the metal member 2 (step S2 in FIG. 5), and the adhesive forms a coating film by preheating the metal member 2 (step S3 in FIG. 5).

[0036] FIG. 6 is a perspective view showing the metal member 2 with the adhesive 32 applied to the bonding surface 2a. The adhesive 32 is in a liquid state. Therefore, if the metal member 2 immediately after applying the adhesive 32 is moved, the adhesive 32 may flow, spread around the bonding surface 2a, or spill. Therefore, preheating is performed on the metal member 2. By performing preheating, the adhesive 32 applied to the bonding surface 2a is appropriately cured and forms a coating film. As a result, the adhesive 32 is fixed on the bonding surface 2a. As a result, it is possible to prevent the adhesive 32 from flowing on the bonding surface 2a.

[0037] The preheating is performed under the condition of maintaining at a predetermined temperature of 60°C or higher and 150°C or lower for a certain period of time in an air atmosphere. If the temperature of the preheating is less than 60°C, the coating of the adhesive 32 is insufficient and the flow cannot be prevented. If the temperature of the preheating is greater than 150°C, the reaction of the adhesive 32 proceeds too much and it cures more than necessary, which may reduce the bonding strength between the resin member 4 and the metal member 2 to be molded later. Also, the holding time set for the preheating is the minimum time required for the coating of the adhesive 32 and is a time that does not cure it more than necessary.

[0038] The metal member 2 after preheating is set in the molding die 10 (step S4 in FIG. 5). Referring to FIG. 2, when setting the metal member 2, the first mold part 12a and the second mold part 12b are separated. At this time, the first space s1 is exposed to the outside as a recess on the parting surface 12b1 of the second mold part 12b.

[0039] The metal member 2 is inserted into the first space s1 exposed to the outside. When the metal member 2 is inserted into the first space s1, the first mold part 12a and the second mold part 12b are combined. Thereby, the attachment of the metal member 2 to the mold 10 is completed.

[0040] At this time, the opening s3 coincides with the joint surface 2a of the metal member 2 as described above. Therefore, the surface 32a (FIG. 6) of the adhesive 32 on the joint surface 2a is exposed from the opening s3 to the second space s2.

[0041] Here, the mold body 12 of the mold 10 is preheated to a predetermined temperature in advance. Also, the temperature of the mold body 12 is maintained at a predetermined temperature even after the metal member 2 is set. At this time, the temperature of the mold body 12 is the same as the temperature during preheating and is maintained at a predetermined temperature of 60°C or higher and 150°C or lower. Therefore, by being set in the mold 10, the metal member 2 is heated following the preheating.

[0042] When the metal member 2 is set in the mold 10 and the heating by the mold 10 is started, next, infrared light is emitted from the spectroscopic analyzer 17 (step S5 in FIG. 5). As described above, the infrared light is emitted from the light projecting part 14 toward the virtual surface F. Therefore, the infrared light projected from the light projecting part 14 is irradiated onto the surface 32a of the adhesive 32 exposed from the opening s3. The infrared light irradiated onto the adhesive 32 is reflected by the adhesive 32. Therefore, while the irradiation of the infrared light onto the adhesive 32 continues, the reflected light of the infrared light is generated.

[0043] Therefore, while the irradiation of the infrared light to the adhesive 32 continues, the light receiving unit 16 receives the reflected light of the infrared light emitted from the light projecting unit 14, and guides the reflected light to the spectroscope 24. Therefore, when the infrared light is emitted, promptly, the spectroscopic analyzer 17 performs quantitative analysis (in FIG. 5, step S6). The spectroscopic analyzer 17 obtains a value A indicating the amount of substance of the curing agent by spectroscopically analyzing the reflected light. It is determined whether the obtained value A is a value that is equal to or greater than the lower limit value TL and equal to or less than the upper limit value TU (in FIG. 5, step S7). When the value A is smaller than the lower limit value TL or larger than the upper limit value, step S7 in FIG. 5 is repeated.

[0044] FIG. 7A is a diagram showing an example of a graph indicating the absorbance obtained by the spectroscopic analyzer 17. In FIG. 7A, a graph in the case where the spectroscopic analyzer 17 is FT-IR is shown. In FIG. 7A, the horizontal axis represents the wave number, and the vertical axis represents the absorbance. Here, the wave number w1 is the wave number of the light absorbed by the isocyanate group contained in the curing agent. The peak appearing at the wave number w1 indicates the absorbance by the isocyanate group and is related to the amount of substance of the isocyanate group. That is, the absorbance indicated by the peak at the wave number w1 is converted into the value A by creating a calibration curve of the known amount of substance of the isocyanate group and the absorbance of the isocyanate group and inputting the measured absorbance value into the calibration curve.

[0045] Further, FIG. 7B is a diagram showing another example of a graph indicating the absorbance obtained by the spectroscopic analyzer 17. In FIG. 7B, a graph in the case where the spectroscopic analyzer 17 is ND-IR is shown. In FIG. 7B, the horizontal axis represents the wavelength, and the vertical axis represents the absorbance. Here, w2 is the wavelength of the light absorbed by the isocyanate group contained in the curing agent. The peak appearing at the wavelength w2 indicates the absorbance by the isocyanate group and is related to the amount of substance of the isocyanate group. That is, the absorbance indicated by the peak at the wavelength w2 is converted into the value A by creating a calibration curve of the known amount of substance of the isocyanate group and the absorbance of the isocyanate group and inputting the measured absorbance value into the calibration curve.

[0046] Immediately after the metal member 2 is set in the molding die 10, the adhesive 32 is preheated, but the reaction of the adhesive 32 has not sufficiently progressed. Therefore, a relatively large number of isocyanate groups of the isocyanate compound contained in the adhesive 32 are present. For this reason, as shown in FIGS. 7A and 7B, the absorbance at the wave number w1 is greater than the upper limit value TU.

[0047] After the metal member 2 is set in the molding die 10 and heated by the molding die 10, the reaction of the adhesive 32 proceeds. Therefore, the isocyanate groups contained in the adhesive 32 gradually decrease with the passage of time. The absorbance at the wave number w1 (wavelength w2) also gradually decreases with the passage of time. Therefore, when a predetermined time has elapsed since the heating by the molding die 10 was started, the absorbance at the wave number w1 (wavelength w2) becomes equal to or greater than the lower limit value TL and equal to or less than the upper limit value TU.

[0048] When the absorbance (value A) at the wave number w1 (wavelength w2) becomes a value equal to or greater than the lower limit value TL and equal to or less than the upper limit value TU, the injection of the molten resin into the second space s2 is started (step S8 in FIG. 5). When the injection of the molten resin is completed and the resin member 4 is molded, the molding of the composite material 1 is completed. Thereafter, the mold body 12 is divided and the composite material 1 is taken out.

[0049] According to the molding die 10 according to the above configuration, since the light projecting unit 14 emits infrared light toward the virtual surface F corresponding to the opening s3, the adhesive 32 applied to the joint surface 2a of the metal member 2 inserted into the first space s1 is irradiated with infrared light. Further, since the light receiving window 28 that transmits the reflected light is provided on the opposing surface 12a11 that faces the virtual surface F, the light receiving unit 16 can take in the reflected light of the infrared light irradiated to the adhesive 32 through the light receiving window 28 and can guide the reflected light to the spectroscope 24. As a result, the spectroscopic analyzer 17 can quantitatively analyze the isocyanate groups, which are the functional groups of the curing agent components contained in the adhesive 32, by spectroscopically analyzing the reflected light, and can acquire the state of the adhesive 32 on the surface of the metal member 2 disposed in the mold body 12. As a result, an injection molding machine (not shown) can start injecting the molten resin into the second space s2 when the state of the adhesive 32 is appropriate, and a composite material having stable strength can be obtained by this manufacturing method.

[0050] Further, the manufacturing method of the composite material 1 of the present embodiment includes applying an adhesive 32 containing a main agent and a curing agent to the bonding surface 2a of the metal member 2, forming the adhesive 32 into a coating film by heating the metal member 2, inserting the metal member 2 into the first space s1 of the heated mold body 12, heating the metal member 2, irradiating the adhesive 32 on the bonding surface 2a with infrared light emitted from the light projecting unit 14, and causing the spectroscope 24 to acquire a value indicating the amount of substance of the curing agent based on the reflected light guided to the spectroscope 24 by the light receiving unit 16. When the value A indicating the amount of substance is within a predetermined numerical range, starting the injection of the molten resin into the second space is included.

[0051] According to this configuration, due to the heating of the metal member 2 by the molding die 10, the reaction between the organic compound containing the hydroxyl group of the main agent and the isocyanate compound of the curing agent proceeds, and the amount of substance of the isocyanate groups possessed by the isocyanate compound decreases (in FIG. 5, step S4). During this period, the adhesive 32 can be irradiated with infrared light, and a value A indicating the amount of substance of the isocyanate groups can be acquired based on the reflected light (in FIG. 5, steps S5 and S6). In this way, this configuration can acquire the state of the adhesive 32 while promoting the reaction of the adhesive 32 on the surface of the metal member 2 disposed in the mold body 12. Therefore, if the lower limit value TL and the upper limit value TU are preset to appropriate values as the timing for injecting the molten resin into the second space s2, the injection of the molten resin can be started when the value A in the adhesive 32 in the mold body 12 is appropriate. As a result, a composite material having stable strength can be obtained.

[0052] In addition, in the present embodiment, the light projecting unit 14 has a light projecting window 18 provided on the facing surface 12a11 and capable of transmitting infrared light, and the infrared light is emitted from the light projecting window 18 toward the virtual surface F. Therefore, the infrared light can be emitted so that the infrared light is effectively reflected toward the light receiving window 28 on the facing surface 12a11.

[0053] In the present embodiment, the optical axis of the infrared light emitted from the light projecting unit 14 is orthogonal to the window lid 18a, and the light receiving axis of the light receiving unit 16 is orthogonal to the window lid 28a. However, the present invention is not necessarily limited to this embodiment. Regarding the light receiving unit 16, the optical axis of the infrared light and the light receiving axis of the light receiving unit 16 can be changed so that the reflected light is received more effectively.

[0054] FIG. 8 is a cross-sectional view of the molding die 10 according to the modified example. This modified example is different from the above-described embodiment in that the window lid of the light projecting window 18 and the window lid of the light receiving window 28 are constituted by one window lid, and the optical axis a1 of the infrared light by the light projecting unit 14 is inclined with respect to the window lid, and the light receiving axis a2 of the light receiving unit 16 is inclined with respect to the window lid.

[0055] In FIG. 8, the light projecting / receiving window 38 has a window lid 38a and a window frame 38b. The window lid 38a closes the openings of the passage 12a2 and the passage 12a4. The window lid 38a is formed of, for example, sapphire glass. The window frame 38b holds the window lid 38a. The light projecting side optical fiber 20 and the light receiving side optical fiber 30 are fixed to the window lid 38a. Therefore, the light projecting / receiving window 38 has a function as the window lid of the light projecting unit 14 and a function as the window lid of the light receiving unit 16.

[0056] The light projecting side optical fiber 20 and the light receiving side optical fiber 30 are fixed to the window lid 38a in an inclined state. In Fig. 8, the optical axis a1 of the infrared light by the light projecting unit 14 is inclined with respect to the window lid 38a. The optical axis a1 passes through the point f1 on the virtual plane F. The optical axis a1 is set such that the reflected light reflected at the point f1 coincides with the light receiving axis a2. Note that the optical axis a1 and the light receiving axis a2 take into account refraction and the like at the window lid 38a.

[0057] In this case, the infrared light emitted from the light projecting unit 14 is reflected at the point f1. This reflected light is received by the light receiving unit 16 along the light receiving axis a2. Therefore, the light receiving unit 16 can effectively receive the reflected light.

[0058] 〔Regarding the verification test〕 Next, the verification test conducted on the manufacturing method of the composite material 1 will be described. The test method is a method of setting four heating times by the molding die 10 and measuring the strength of the composite material 1 formed by each heating time. The test methods for each heating time are all under the same conditions except for the heating time by the molding die 10. The strength of the composite material 1 was measured by a tensile test. Among the composite material 1, the part of the metal member 2 and the part of the resin member 4 were attached to a tensile testing machine, and a tensile test was conducted to measure the shear strength between the metal member 2 and the resin member 4.

[0059] Fig. 9 is a graph showing the result of measuring the shear strength between the metal member 2 and the resin member 4 in the composite material 1. In Fig. 9, the horizontal axis is the heating time by the molding die 10. Among the heating times t1 to t4, the heating time t1 is the shortest time, and the heating time t4 is the longest time. When the heating times are t1 and t2, the value A immediately after the elapse of the heating time (immediately before the start of injection of the molten resin) is higher than the upper limit value TU. When the heating time is t3, the value A immediately after the elapse of the heating time (immediately before the start of injection of the molten resin) is a value between the upper limit value TU and the lower limit value TL. When the heating time is t4, the value A immediately after the elapse of the heating time (immediately before the start of injection of the molten resin) is smaller than the lower limit value TL.

[0060] In this test, test pieces were prepared by curing only the adhesive at four heating times, and the tensile test was performed using these test pieces. Note that the heating of the test pieces of only the adhesive is the time obtained by adding the heating time by the molding die 10 and the preheating time.

[0061] In FIG. 9, the vertical axis on the left side indicates the strength of the test piece of only the adhesive. The vertical axis on the right side indicates the shear strength of the composite material 1. Also, in FIG. 9, the bar graph indicates the strength of the test piece of only the adhesive corresponding to each heating time. In FIG. 9, the point P1 indicates the shear strength of the composite material 1 with the heating time t1. Similarly, the points P2 to P4 indicate the shear strengths of the composite material 1 with the heating times t2 to t4.

[0062] As shown in FIG. 9, the strength of the test piece of only the adhesive increases as the heating time increases. On the other hand, in the shear strength of the composite material 1, the shear strength of the composite material 1 with the heating time t3 is the highest. Therefore, the shear strength of the composite material 1 with the heating time t4 is lower than the shear strength of the composite material 1 with the heating time t3. This is because if the heating time by the molding die 10 is made too long more than necessary, the curing of the adhesive 32 proceeds too much, and when the adhesive 32 and the molten resin come into contact, the adhesive 32 and the molten resin are not firmly adhered, so it is considered that the strength as a composite material decreases.

[0063] From this result, it can be seen that if the lower limit value TL and the upper limit value TU are appropriately set so as to include the heating time t3, when the amount of substance of the curing agent in the adhesive 32 in the mold body 12 is appropriate, the injection of the molten resin can be started, and a composite material having a stable strength can be obtained.

[0064] 〔Others〕 The embodiments disclosed this time are illustrative in all respects and not restrictive. The scope of the rights of the present invention is not limited to the above-described embodiments, and includes all modifications within the scope equivalent to the configuration described in the claims.

Explanation of Reference Numerals

[0065] 1 Composite material 2 Metal member 2a Joint surface 4 Resin member 10 Molding die 12 Die body 12a11 Opposing surface 14 Light projecting part 16 Light receiving part 17 Infrared spectroscopic analyzer 18 Light projection window 22 Infrared light source 24 Spectrometer 28 Light receiving window 30 Light receiving side optical fiber 32 Adhesive F Virtual surface S Internal space s1 First space s2 Second space s2a Inner surface s3 Opening

Claims

1. A molding die for molding a composite material having metal members and resin members joined to each other, having a mold body having a first space into which the metal member is inserted, a second space which is a cavity in which the resin member is molded by injection of molten resin, and an internal space including an opening connecting the first space and the second space; a light projecting part that emits infrared light into the second space; a light receiving part that receives the reflected light of the infrared light and guides the reflected light to a spectroscope, the metal member has a joint surface that is exposed from the opening to the second space when the metal member is inserted into the first space, the light projecting part emits the infrared light toward a virtual surface included in an inner surface defining the second space and corresponding to the opening, the light receiving part has a light receiving window provided on an opposing surface included in the inner surface and opposing the virtual surface, and transmitting the reflected light molding die.

2. the light receiving part further has an optical fiber that extends from the light receiving window to the outside of the mold body and guides the reflected light transmitted through the light receiving window to the spectroscope The molding die according to claim 1.

3. the light projecting part has a light projecting window provided on the opposing surface and allowing the infrared light to pass through, the infrared light is emitted from the light projecting window toward the virtual surface The molding die according to claim 1.

4. A method for manufacturing the composite material using the molding die according to claim 1, applying an adhesive containing a main agent and a curing agent to the joint surface of the metal member, forming a coating film of the adhesive by heating the metal member, heating the metal member by inserting the metal member into the first space of the mold body whose temperature has been raised, Irradiate the infrared light emitted from the light projecting unit onto the adhesive on the bonding surface, Cause the spectrometer to obtain a value indicating the amount of substance of the curing agent based on the reflected light guided to the spectrometer by the light receiving unit, When the value indicating the amount of substance is within a predetermined numerical range, start injecting the molten resin into the second space Method for manufacturing a composite material.

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