Mold, device, and method for manufacturing metal-resin composite

Abstract

To provide a mold, an apparatus and a method for manufacturing a metal-resin composite by a set of molds which improve the molding accuracy of a metal member.SOLUTION: A mold 100 for manufacturing a metal-resin composite by press-molding a metal member 10, and integrally molding the press-molded metal member 10 and a resin material has an upper mold 110 and a lower mold 120 sandwiching the metal member 10 and the resin material. The upper mold 110 has a first press surface 111a for press-molding the metal member 10, and a second press surface 111b for integrally molding the metal member 10 and the resin material. A distance d11 between the first press surface 111a and the lower mold 120 is shorter than a distance d12 between the second press surface 111b and the lower mold 120.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a mold, an apparatus, and a method for producing a metal-resin composite body. [Background technology]

[0002] An apparatus for producing a metal-resin composite by press-molding a metal member and a thermosetting resin material is known (for example, Patent Document 1). The metal-resin composite is integrally formed by press-molding a metal member that has been press-molded in advance by a press device separate from the above apparatus with a resin material. In other words, a die for press-molding the metal member and a die for integrally molding the metal member and the resin material are used to produce the metal-resin composite. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-104411 A Summary of the Invention [Problem to be solved by the invention]

[0004] When the metal-resin composite is molded using a set of dies, the metal member is press molded into a predetermined shape, and then the metal member and the resin material are press molded using the dies used for press molding the metal member. In this case, since the cavity of the die is designed according to the shape of the metal-resin composite, that is, the final shape in which the metal member and the resin material are molded together, it is difficult to press mold the metal member along the lower die, and there is a risk of reducing the molding accuracy of the metal member.

[0005] An object of the present invention is to improve the molding accuracy of metal members in a mold, an apparatus, and a method for producing a metal-resin composite body using a set of molds. [Means for solving the problem]

[0006] The first aspect of the present invention is A die for producing a metal-resin composite by press-molding a metal member and integrally molding the press-molded metal member and a resin material, an upper mold and a lower mold that sandwich the metal member and the resin material; The upper mold is A first press surface for press-forming the metal member; a second press surface for integrally molding the metal member and the resin material; Equipped with When the metal member is press-molded, a distance between the first press surface and the lower die is shorter than a distance between the second press surface and the lower die.

[0007] In the case where press molding of a metal member and integral molding of the metal member and the resin material are performed using one set of dies, if the molding surface of the upper die and the molding surface of the lower die are separated by the thickness of the metal member and the resin material when the upper die and the lower die are closed, the metal member cannot be pressed by the molding surface of the upper die and the molding surface of the lower die, and the metal member cannot be molded to conform to the shape of the molding surface of the lower die. In contrast, with this configuration, the distance between the first press surface for molding the metal member and the lower die is shorter than the distance between the second press surface for integral molding the metal member and the resin material and the lower die, so that the metal member easily conforms to the shape of the lower die during press molding of the metal member. As a result, the molding accuracy of the metal member can be improved.

[0008] In a state in which the upper mold and the lower mold are closed, a distance between the first press surface and the lower mold may be set to be at least partially equal to a thickness of the metal member.

[0009] Here, "equally" is a design setting. Also, "equally" is not limited to being equal in the strict sense. In other words, the distance between the first press surface and the lower die does not have to be exactly equal to the thickness of the metal member. "Equally" includes "equally" in the strict sense and a form that is slightly deviated from "equally" in the strict sense within the range of the molding accuracy of the metal member.

[0010] According to this configuration, the distance between the first press surface and the lower die is set to be at least partially equal to the thickness of the metal member, so that the metal member can be molded to conform to the shape of the molding surface of the lower die, thereby improving the molding accuracy of the metal member.

[0011] The metal-resin composite has, in a cross section perpendicular to the longitudinal direction, a bottom wall portion extending horizontally and side wall portions rising from both ends of the bottom wall portion, and the upper mold includes the first press surface and the second press surface, and is provided with a first molding upper surface that molds the bottom wall portion and a second molding upper surface that molds the side wall portion, and the first press surface may be continuous with the second molding upper surface.

[0012] According to this configuration, the periphery of the corner formed by the bottom wall and the side wall of the metal-resin composite body can be pressed by the first press surface, so that the forming accuracy of the corner can be improved.

[0013] The first press surface may be a plurality of first press surfaces arranged discontinuously along the longitudinal direction.

[0014] According to this configuration, since a plurality of first press surfaces are arranged discontinuously along the longitudinal direction, when the metal member and the resin material are integrally molded, the resin material flows into between the second molding upper surface and the metal member through the portion where the first press surfaces are not arranged, thereby forming a side wall portion in which the metal member and the resin material are integrally molded.

[0015] The upper mold may include an upper mold body on which the second press surface is formed, and a movable part on which the first press surface is formed and which is movably attached to the upper mold body, and the movable part may be movable between a protruding position where the first press surface is closer to the lower mold than the second press surface, and a retracted position where the first press surface and the second press surface are flush with each other.

[0016] According to this configuration, the metal member is press-molded with the movable part in the protruding position, and the metal member and the resin material are integrally molded with the movable part in the retracted position, so that no portions where the resin material has been removed are formed in the molded metal-resin composite, and reduction in strength of the metal-resin composite can be suppressed.

[0017] A second aspect of the present invention is An apparatus for producing a metal-resin composite by press-molding a metal member and integrally molding the press-molded metal member and a resin material, comprising: an upper mold and a lower mold that sandwich the metal member and the resin material; a drive unit that moves at least one of the upper mold and the lower mold in a vertical direction; Equipped with The upper mold is A first press surface for press-forming the metal member; a second press surface for integrally molding the metal member and the resin material; Equipped with When the metal member is press-molded, the distance between the first press surface and the lower die is shorter than the distance between the second press surface and the lower die.

[0018] In the case where press molding of a metal member and integral molding of the metal member and the resin material are performed using one set of dies, if the molding surface of the upper die and the molding surface of the lower die are separated by the thickness of the metal member and the resin material when the upper die and the lower die are closed, the metal member cannot be pressed by the molding surface of the upper die and the molding surface of the lower die, and the metal member cannot be molded to conform to the shape of the molding surface of the lower die. In contrast, with this configuration, the distance between the first press surface for molding the metal member and the lower die is shorter than the distance between the second press surface for integral molding the metal member and the resin material and the lower die, so that the metal member easily conforms to the shape of the lower die during press molding of the metal member. As a result, the molding accuracy of the metal member can be improved.

[0019] A third aspect of the present invention is A method for producing a metal-resin composite by press-molding a metal member and integrally molding the press-molded metal member and a resin material, comprising: preparing an upper mold having a first press surface for press-molding the metal member and a second press surface for integrally molding the metal member and the resin material, and a lower mold; the upper die and the lower die are closed, and the metal member is press-formed by the first press surface of the upper die and the lower die; The upper mold and the lower mold are opened, and the resin material is placed on the press-molded metal member; The upper die and the lower die are closed, and the metal member and the resin material are integrally molded by the second press surface of the upper die and the lower die. Including, wherein, when press-forming the metal member, the distance between the first press surface and the lower die is shorter than the distance between the second press surface and the lower die.

[0020] In the case where press molding of a metal member and integral molding of the metal member and the resin material are performed using one set of dies, if the molding surface of the upper die and the molding surface of the lower die are separated by the thickness of the metal member and the resin material when the upper die and the lower die are closed, the metal member cannot be pressed by the molding surface of the upper die and the molding surface of the lower die, and the metal member cannot be molded to conform to the shape of the molding surface of the lower die. In contrast, with this configuration, the distance between the first press surface for molding the metal member and the lower die is shorter than the distance between the second press surface for integral molding the metal member and the resin material and the lower die, so that the metal member easily conforms to the shape of the lower die during press molding of the metal member. As a result, the molding accuracy of the metal member can be improved. Effect of the Invention

[0021] According to the present invention, in the mold, the device, and the method for producing a metal-resin composite body using one set of molds, it is possible to improve the molding accuracy of the metal member. [Brief description of the drawings]

[0022] [Figure 1]1 is a perspective view of a metal-resin composite according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Diagram 3] FIG. 2 is a perspective view of an upper mold according to the first embodiment. [Figure 4] FIG. 3 is a cross-sectional view showing a first step of a method for producing a metal-resin composite according to the first embodiment. [Diagram 5] 4 is a cross-sectional view showing a second step of the method for producing the metal-resin composite body in the first embodiment. FIG. [Figure 6] FIG. 4 is a cross-sectional view showing a third step of the method for producing a metal-resin composite body in the first embodiment. [Figure 7] FIG. 4 is a cross-sectional view showing a fourth step of the method for producing a metal-resin composite body in the first embodiment. [Figure 8] FIG. 4 is a cross-sectional view showing a fifth step of the method for producing a metal-resin composite body in the first embodiment. [Figure 9] FIG. 11 is a cross-sectional view showing a first step of a method for producing a metal-resin composite according to a second embodiment. [Figure 10] FIG. 11 is a cross-sectional view showing a second step of the method for producing a metal-resin composite according to the second embodiment. [Figure 11] FIG. 11 is a cross-sectional view showing a third step of the method for producing a metal-resin composite according to the second embodiment. [Figure 12] FIG. 11 is a cross-sectional view showing a fourth step of the method for producing a metal-resin composite according to the second embodiment. [Figure 13] FIG. 11 is a cross-sectional view showing a fifth step of the method for producing a metal-resin composite according to the second embodiment. [Figure 14] FIG. 11 is a cross-sectional view showing a sixth step of the method for producing a metal-resin composite according to the second embodiment. [Figure 15] FIG. 11 is a cross-sectional view showing a seventh step of the method for producing a metal-resin composite according to the second embodiment. [Figure 16] FIG. 11 is a cross-sectional view showing a first step of a method for producing a metal-resin composite according to a third embodiment. [Figure 17]FIG. 11 is a cross-sectional view showing a second step of the method for producing a metal-resin composite according to the third embodiment. [Figure 18] FIG. 11 is a cross-sectional view showing a third step of the method for producing a metal-resin composite according to the third embodiment. [Figure 19] FIG. 11 is a cross-sectional view showing a fourth step of the method for producing a metal-resin composite according to the third embodiment. [Figure 20] FIG. 11 is a cross-sectional view showing a fifth step of the method for producing a metal-resin composite according to the third embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A mold, an apparatus, and a method for manufacturing a metal-resin composite body will be described below as embodiments of the present invention with reference to the accompanying drawings.

[0024] (First embodiment) 1 and 2, the metal resin composite 1 produced in this embodiment includes a metal plate (metal member) 10 and a resin material 20. As shown in FIG. 2, the metal resin composite 1 has a hat shape in a cross section perpendicular to the longitudinal direction. In detail, the metal resin composite 1 is configured by adhering the resin material 20 to the inner surface (concave surface) of the hat-shaped metal plate 10. However, the shape of the metal resin composite 1 is not limited to a hat shape and may be any shape.

[0025] The metal-resin composite 1 has a bottom wall 2 extending in the horizontal direction, side wall 3 rising from both ends of the bottom wall 2, and a flange 4 extending horizontally outward from the side wall 3. The side wall 3 is provided with a step 3a in which the thickness of the resin material 20 decreases from the bottom wall 2 toward the flange 4. The bottom wall 2 is made of a metal plate 10 and a resin material 20, the side wall 3 is made of a metal plate 10 and a resin material 20, and the flange 4 is made of only the metal plate 10. More specifically, the side wall 3 is made of the metal plate 10 and the resin material 20 on the bottom wall 2 side from the step 3a, and is made of only the metal plate 10 on the flange 4 side from the step 3a.

[0026] As shown in FIG. 1, the bottom wall portion 2 is provided with eight holes 2a (only five are shown in FIG. 1). The holes 2a are spaces in which no resin material 20 exists. Four holes 2a are provided at each end in the short direction of the bottom wall portion 2. The holes 2a are also arranged intermittently along the longitudinal direction of the bottom wall portion 2. More specifically, the holes 2a are arranged at equal intervals along the longitudinal direction of the bottom wall portion 2.

[0027] A mold 100, an apparatus 50, and a method for producing the metal resin composite 1 in this embodiment will be described with reference to Figures 3 to 8. In the drawings, the horizontal direction is indicated as the X direction, and the vertical direction (up and down direction) is indicated as the Y direction.

[0028] In this embodiment, two press moldings are performed by sequentially performing the first to fifth steps shown in Figures 4 to 8. The first press is performed in the first to third steps shown in Figures 4 to 6, and the second press is performed in the third to fifth steps shown in Figures 6 to 8.

[0029] 4, an apparatus 50 for producing a metal resin composite 1 in this embodiment has a mold 100, a drive unit 130 that drives the mold 100, and a heating unit 140 that heats the mold. Note that the drive unit 130 and the heating unit 140 may be known units capable of performing press molding, and are shown only in FIG. 4 as a conceptual diagram without showing details, and are omitted from FIG. 5 onwards.

[0030] The mold 100 is for press-molding the metal plate 10 and the resin material 20 to manufacture the metal resin composite 1. The mold 100 has an upper mold 110 and a lower mold 120 that sandwich the metal plate 10 and the resin material 20. In this embodiment, the upper mold 110 is configured as a punch, and the lower mold 120 is configured as a die. The upper mold 110 can be moved in the vertical direction by the drive unit 130, that is, it is configured to be able to approach and move away from the lower mold 120. However, the driving mode of the mold 100 by the drive unit 130 is not particularly limited, and the drive unit 130 can move at least one of the upper mold 110 and the lower mold 120 in the vertical direction.

[0031] 3 and 4, the upper mold 110 has a first molding upper surface 111 which molds the bottom wall portion 2 (see FIG. 1), a second molding upper surface 112 which molds the side wall portion 3 (see FIG. 1), and a third molding upper surface 113 which molds the flange portion 4 (see FIG. 1). In this embodiment, the first molding upper surface 111 and the third molding upper surface 113 are configured as horizontal surfaces, and the second molding upper surface 112 connects the first molding upper surface 111 and the third molding upper surface 113 and is configured to be inclined from the vertical direction.

[0032] In this embodiment, the upper mold 110 is provided with eight protrusions 114 protruding downward from the first molding upper surface 111. Four protrusions 114 are provided on each end of the first molding upper surface 111 in the short direction. The protrusions 114 are also arranged intermittently along the longitudinal direction of the upper mold 110. More specifically, the protrusions 114 are arranged at equal intervals along the longitudinal direction of the upper mold 110.

[0033] The first molding upper surface 111 includes a first press surface 111a provided at the lower end of the protrusion 114, and a second press surface 111b provided above the protrusion 114. The first press surface 111a and the second press surface 111b are configured as horizontal surfaces. In addition, both the first press surface 111a and the second press surface 111b are provided so as to be continuous with the second molding upper surface 112.

[0034] In this embodiment, a step 112a is provided on the second molding upper surface 112. The step 112a is provided so as to rise one step from the first molding upper surface 111 toward the third molding upper surface 113.

[0035] The lower mold 120 has a first molding lower surface 121 for molding the bottom wall portion 2 (see FIG. 1), a second molding lower surface 122 for molding the side wall portion 3 (see FIG. 1), and a third molding lower surface 123 for molding the flange portion 4 (see FIG. 1). In this embodiment, the first molding lower surface 121 and the third molding lower surface 123 are configured as horizontal surfaces, and the second molding lower surface 122 connects the first molding lower surface 121 and the third molding lower surface 123 and is configured to be inclined from the vertical direction. The first molding lower surface 121 is disposed opposite the first molding upper surface 111, the second molding lower surface 122 is disposed opposite the second molding upper surface 112, and the third molding lower surface 123 is disposed opposite the third molding upper surface 113.

[0036] In the first step shown in FIG. 4, a flat metal plate 10 before molding is placed on a lower die 120.

[0037] In the second step shown in FIG. 5, the upper die 110 is lowered, and the metal sheet 10 is sandwiched between the upper die 110 and the lower die 120 to be press-formed into a generally hat-shape. When the upper die 110 and the lower die 120 are closed, the distance d11 between the first press surface 111a of the first molding upper surface 111 and the first molding lower surface 121 is equal to the thickness t of the metal sheet 10 (d11=t). By setting the distance d11 equal to the thickness t of the metal sheet 10, the forming accuracy of the metal sheet 10 can be improved. In addition, the distance d12 between the second press surface 111b of the first molding upper surface 111 and the first molding lower surface 121 is larger than the thickness t of the metal sheet 10 (d1>t), and the distance d3 between the third molding upper surface 113 and the third molding lower surface 123 is approximately equal to the thickness t of the metal sheet 10 (d3=t). Further, the distance d21 between the second molding upper surface 112 and the second molding lower surface 122 below the step 112a is larger than the thickness t of the metal plate 10 (d21>t), and the distance d22 between the second molding upper surface 112 and the second molding lower surface 122 above the step 112a is approximately equal to or slightly larger than the thickness t of the metal plate 10 (d22=t or d22>t). In particular, by setting the distance d22 equal to the thickness t of the metal plate 10, the filling pressure of the resin material 20 in the subsequent process can be increased. In this process, the resin material 20 (see Figs. 4 to 7) has not yet been filled, and only the metal plate 10 is sandwiched between the upper mold 110 and the lower mold 120. A cavity C for filling the resin material 20 is provided between the first and second molding upper surfaces 111-112 and the first and second molding lower surfaces 121-122 (specifically, the metal plate 10).

[0038] In the third step shown in FIG. 6, the upper mold 110 is raised. At this time, the metal plate 10 is molded into a shape close to the final shape (hat-shaped in this embodiment). Then, a sheet-shaped resin material 20 (also called prepreg) cut to a required size is placed on the metal plate 10. In this embodiment, the resin material 20 is cured under high temperature and high pressure by a molding method called SMC (Sheet Molding Compound) method (see the fourth step described later). In this embodiment, a fiber reinforced plastic (FRP) in which glass fiber or carbon fiber is impregnated into resin is used as the resin material 20. In this embodiment, the resin material 20 has thermosetting properties. In this step, the resin material 20 has not yet been heated, i.e., has not yet been cured. The resin material 20 does not need to be in a sheet shape and can have any shape.

[0039] In the fourth step shown in Fig. 7, the upper die 110 is lowered, and the metal plate 10 and the resin material 20 are sandwiched between the upper die 110 and the lower die 120 to be press-molded into a hat shape. At this time, the cavity C is filled with the resin material 20. That is, the resin material 20 cut to a required size by the SMC method is poured into the die 100 and cured under high temperature and high pressure. In this embodiment, the cavity C refers to the space below the step 112a formed by the upper die 110 and the lower die 120 (specifically, the metal plate 10) being sandwiched between them.

[0040] When the resin material 20 is filled into the cavity C, the resin material 20 passes between the protrusions 114 (shown in FIG. 3) of the upper mold 110 and flows into the space between the second molding upper surface 112 and the second molding lower surface 122. As a result, the resin material 20 is contained in the side wall portion 3 (shown in FIG. 2), and a hole 2a (shown in FIG. 1) is formed in the bottom wall portion 2 (shown in FIG. 1) at a position corresponding to the protrusion 114.

[0041] 8, the upper die 110 is raised. The metal plate 10 is formed into a final shape (hat-shaped in this embodiment), and the resin material 20 is adhered to the upper surface (concave surface of the hat-shape) of the metal plate 10, forming a metal-resin composite body 1. In this manner, the hat-shaped metal-resin composite body 1 is manufactured as a product.

[0042] In the case where the press molding of the metal plate 10 and the integral molding of the metal plate 10 and the resin material 20 are performed using one pair of dies, if a die is used in which the molding surface of the upper die and the molding surface of the lower die are separated by the thickness of the metal plate 10 and the resin material 20 when the upper die and the lower die are closed, the metal plate 10 cannot be pressed by the molding surface of the upper die and the molding surface of the lower die, and the metal plate 10 cannot be molded to conform to the shape of the molding surface of the lower die. In contrast, according to this embodiment, the first press surface 111a for molding the metal plate 10 is closer to the lower die than the second press surface 111b for integrally molding the metal plate 10 and the resin material 20, so that the metal plate 10 easily conforms to the shape of the lower die 120 during press molding of the metal plate 10. As a result, the molding accuracy of the metal plate 10 can be improved.

[0043] Since the distance d11 between the first pressing surface 111a and the first shaping lower surface 121 of the lower die 120 is set to be at least partially equal to the thickness t of the metal sheet 10, the metal sheet 10 can be shaped to conform to the shape of the first shaping lower surface 121 of the lower die 120. As a result, the shaping accuracy of the metal sheet 10 can be improved.

[0044] Since the first press surface 111a is provided continuous with the second molding upper surface 112, the periphery of the corner formed by the bottom wall portion 2 and the side wall portion 3 of the metal-resin composite 1 can be pressed by the first press surface 111a, thereby improving the molding accuracy of the corner.

[0045] Since a plurality of first press surfaces 111a are arranged intermittently along the longitudinal direction, when the metal plate 10 and the resin material 20 are integrally molded, the resin material 20 flows between the second molding upper surface 112 and the metal plate 10 through the portion where the first press surfaces 111a are not arranged. This allows the side wall portion 3 in which the metal plate 10 and the resin material 20 are integrally molded to be formed.

[0046] The bottom wall 2 of the metal resin composite 1 manufactured by the mold 100 of this embodiment has the holes 2a formed at positions corresponding to the protrusions 114, which reduces the weight of the metal resin composite 1. In addition, in the portion of the bottom wall 2 where the holes 2a are formed, the metal plate 10 can be subjected to a process such as drilling without removing the resin material 20.

[0047] Second embodiment A mold 100, an apparatus 50, and a method for producing the metal-resin composite body 1 in the second embodiment will be described with reference to FIGS.

[0048] 9 to 15, an upper die 110 has a separate punch 110a and a holder 110b. Other than this, the present embodiment is substantially the same as the first embodiment. Therefore, the description of the parts shown in the first embodiment may be omitted.

[0049] In this embodiment, the upper die 110 has a holder 110b for holding the metal plate 10 and a punch 110a for forming the metal plate 10. The holder 110b and the punch 110a can be moved independently in the vertical direction by a drive unit 130 (see FIG. 2).

[0050] In this embodiment, two press moldings are performed by sequentially performing steps 1 to 7 shown in Figures 9 to 15. The first press is performed in steps 1 to 4 shown in Figures 9 to 12, and the second press is performed in steps 4 to 7 shown in Figures 12 to 15.

[0051] 9 to 12, in the first pressing of steps 1 to 4, unlike the first embodiment, the holder 110b descends before the punch 110a to press the metal sheet 10. Then, the punch 110a descends to press the metal sheet 10. Steps 1 to 4 of this embodiment are substantially the same as steps 1 to 3 of the first embodiment, except for the independent driving of the punch 110a and the holder 110b.

[0052] 12 to 15, the second pressing in steps 4 to 7 is also different from the first embodiment in that the holder 110b descends before the punch 110a to press the metal sheet 10. Next, the punch 110a descends to press the metal sheet 10. Steps 4 to 7 of this embodiment are substantially the same as steps 3 to 5 of the first embodiment, except for the independent driving of the punch 110a and the holder 110b.

[0053] Third embodiment A mold 100, an apparatus 50, and a method for producing the metal-resin composite body 1 in the third embodiment will be described with reference to FIGS.

[0054] 16 to 20, an upper mold 110 has an upper mold body 115 and a movable part 116. Other than this, the present embodiment is substantially the same as the first embodiment. Therefore, the description of the parts shown in the first embodiment may be omitted.

[0055] In this embodiment, the upper die 110 has an upper die body 115 on which the second press surface 111b is formed, and a movable part 116 on which the first press surface 111a is formed and which is attached movably relative to the upper die body 115. The movable part 116 is movable by a cylinder (not shown) between a protruding position where the first press surface 111a is closer to the lower die 120 than the second press surface 111b is, and a retracted position where the first press surface 111a and the second press surface 111b are flush with each other.

[0056] In this embodiment, two press moldings are performed by sequentially performing the first to fifth steps shown in Figures 16 to 20. The first press is performed in the first to third steps shown in Figures 16 to 18, and the second press is performed in the third to fifth steps shown in Figures 18 to 20.

[0057] 16 to 18, in this embodiment, the metal plate 10 is press-formed with the movable part 116 in the protruding position. The first to third steps of this embodiment are substantially the same as the first to third steps of the first embodiment.

[0058] 18 to 20, in the second pressing of the third to fifth steps, the metal plate 10 and the resin material 20 are press-molded with the movable part 116 in the retracted position, unlike the first embodiment. The second to fifth steps of this embodiment are substantially the same as the third to fifth steps of the first embodiment, except for the movement of the movable part 116.

[0059] According to this embodiment, the metal plate 10 is press-molded with the movable part 116 in the protruding position, and the metal plate 10 and the resin material 20 are integrally molded with the movable part 116 in the retracted position, so that no portion where the resin material 20 has been removed is formed in the molded metal resin composite 1, and a decrease in the strength of the metal resin composite 1 can be suppressed.

[0060] Although the specific embodiment of the present invention and its modified examples have been described above, the present invention is not limited to the above-mentioned embodiment, and various modifications can be made within the scope of the present invention. For example, an appropriate combination of the contents of each embodiment and modified examples may be one embodiment of the present invention.

[0061] Alternatively, a thermoplastic resin impregnated with glass fiber or carbon fiber may be used as the resin material 20. In this case, the resin material 20 is heated and softened before being poured into the mold 100. Then, the resin material 20 is cooled and hardened on the metal plate 10 in the mold 100, thereby producing the metal resin composite 1.

[0062] The first press surface 111a of the upper mold 110 is provided at both ends in the short direction of the first molding upper surface 111, but is not limited thereto. For example, the first press surface 111a may be provided at the center of the first molding upper surface 111. In this case, molding accuracy at the center of the bottom wall portion 2 can be improved. Also, for example, the first press surface 111a may be provided at a location corresponding to a portion where drilling or the like is required in the metal plate 10 after the integral molding of the metal-resin composite 1. In this case, drilling or the like can be performed on the metal plate 10 in that portion without removing the resin material 20.

[0063] In the metal resin composite 1, an adhesive layer may be provided between the metal plate 10 and the resin material 20. In this case, by providing the adhesive layer, the metal plate 10 and the resin material 20 can be firmly molded into one body. [Explanation of symbols]

[0064] 1 Metal resin composite 2 Bottom wall 3 Side wall 3a Step part 4 Flange 10 Metal plate (metal parts) 20 Resin material 50 equipment 100 Molds 110 Upper mold 110a Punch 110b Holder 111 1st molding top surface 111a 1st press surface 111b 2nd press surface 112 Second molding top surface 112a Step 113 Third molding top surface 115 Upper mold body 116 Moving parts 120 Lower mold 121 First molding bottom surface 122 Second molding bottom surface 123 Third molding bottom surface 130 Drive unit 140 Heating section C Cavity

Claims

1. A die for producing a metal-resin composite by press-molding a metal member and then integrally molding the press-molded metal member and a resin material, the die being used for both the press molding of the metal member and the integral molding of the metal member and the resin material, the mold includes an upper mold and a lower mold that sandwich the metal member and the resin material, The upper mold is A first press surface for press-forming the metal member; a second press surface for integrally molding the metal member and the resin material; Equipped with When the metal member is press-molded, a distance between the first press surface and the lower die is shorter than a distance between the second press surface and the lower die, The metal-resin composite body has, in a cross section perpendicular to the longitudinal direction, a bottom wall portion extending horizontally and side wall portions rising from both ends of the bottom wall portion, A die, wherein a plurality of the first press surfaces are arranged intermittently along the longitudinal direction.

2. The mold according to claim 1 , wherein when the upper mold and the lower mold are closed, the distance between the first press surface and the lower mold is set to be at least partially equal to the thickness of the metal member.

3. The upper mold is a first molding upper surface including the first press surface and the second press surface and configured to mold the bottom wall portion; a second molding upper surface that molds the side wall portion; Equipped with The mold according to claim 1 or 2, wherein the first press surface is continuous with the second upper molding surface.

4. The upper mold is An upper mold body on which the second press surface is formed; a movable portion on which the first press surface is formed and which is movably attached to the upper mold body; Equipped with 4. The mold according to claim 1, wherein the movable part is movable between a protruding position where the first press surface is closer to the lower mold than the second press surface, and a retracted position where the first press surface and the second press surface are flush with each other.

5. An apparatus for manufacturing a metal-resin composite by press-molding a metal member and then integrally molding the press-molded metal member and a resin material, the apparatus being used for both the press molding of the metal member and the integral molding of the metal member and the resin material, an upper mold and a lower mold that sandwich the metal member and the resin material; a drive unit that moves at least one of the upper mold and the lower mold in a vertical direction; Equipped with The upper mold is A first press surface for press-forming the metal member; a second press surface for integrally molding the metal member and the resin material; Equipped with When the metal member is press-molded, a distance between the first press surface and the lower die is shorter than a distance between the second press surface and the lower die, The metal-resin composite body has, in a cross section perpendicular to the longitudinal direction, a bottom wall portion extending horizontally and side wall portions rising from both ends of the bottom wall portion, The apparatus comprises a plurality of first press surfaces disposed discontinuously along the longitudinal direction.

6. A method for producing a metal-resin composite by press-molding a metal member and integrally molding the press-molded metal member and a resin material, comprising: preparing an upper mold having a first press surface for press-molding the metal member and a second press surface for integrally molding the metal member and the resin material, and a lower mold; closing the upper die and the lower die, and press-forming the metal member by the first press surface of the upper die and the lower die; The upper mold and the lower mold are opened, and the resin material is placed on the press-molded metal member; The upper die and the lower die are closed, and the metal member and the resin material are integrally molded by the second press surface of the upper die and the lower die. Including, When press forming the metal member, a distance between the first press surface and the lower die is shorter than a distance between the second press surface and the lower die.

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