Metal-resin composite manufacturing apparatus and manufacturing method

Abstract

To prevent a resin material from flowing into a gap between a mold and an extrusion material, when a metal-resin composite is manufactured by integrating the resin material with the extrusion material by press molding.SOLUTION: A manufacturing method of a metal-resin composite body for integrating a resin material 300 with a metal extrusion material by press molding includes the steps of: preparing a first mold 10 for forming a storage part 15 for storing at least a part of the extrusion material, and a second mold 20 which is movable in an opening / closing direction relative to the mold; arranging the resin material on the first mold after storing the extrusion material; moving the second mold in a mold closing direction; forming a cavity 40 by the surface of the extrusion material and the mold 2; pressurizing the resin material; and filling the cavity with the pressurized resin material. The extrusion material has projections 231 and 232 which project from the surface and are brought into close contact with the storage part in a state in which the extrusion material is stored in the storage part. In the filling, the projections are brought into close contact with the storage part or its circumference by molding pressure imparted to the extrusion material from the mold, and the cavity is blocked from a gap 51 between the inner face of the storage part and the surface of the extrusion material.SELECTED DRAWING: Figure 7

Description

[Technical Field]

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

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

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2017-119422 [Patent Document 2] Japanese Patent Application Publication No. 2020-104411 Summary of the Invention [Problem to be solved by the invention]

[0004] When applying the hot press exemplified in Patent Document 2 to the manufacture of composites containing aluminum extrusions, it is considered necessary to prepare a die that takes into account the tolerances of the aluminum extrusions and forms a suitable gap between the die and the aluminum extrusions, which are assumed to have standard dimensions. This allows the aluminum extrusions, formed within tolerances, to be properly placed in the die each time a composite is manufactured. On the other hand, aluminum extrusions are hot extruded as taught in Patent Document 1. Therefore, twisting and bending are likely to occur during extrusion, making it difficult to achieve high dimensional accuracy for the aluminum extrusions.

[0005] Considering the low dimensional accuracy of aluminum extrusions, it is considered necessary to make the gap between the die and the aluminum extrusion significantly larger than the gap between the mating surfaces of the dies. This can lead to unintended resin flow into the gap between the die and the aluminum extrusion during hot pressing, reducing the production efficiency of the composite. For example, the resin solidifies in the gap, increasing the mold release resistance. After demolding, the cumbersome task of peeling off the unnecessary resin that has solidified in the gap is required. To avoid a shortage of resin on the aluminum extrusion, it is necessary to fill the gap with extra resin in anticipation of the amount that will be peeled off.

[0006] An object of the present invention is to suppress the flow of resin material into the gap between a mold and an extruded material when a metal resin composite is produced by press-molding a resin material onto an extruded material. [Means for solving the problem]

[0007] A first aspect of the present invention provides a method for manufacturing a metal-resin composite by press-molding a resin material onto a metallic extrusion material, the method comprising: preparing a mold including a first mold that forms a storage section that stores at least a portion of the extrusion material, and a second mold that is movable in an opening and closing direction relative to the first mold; storing the extrusion material in the storage section and placing the resin material on the first mold; moving the second mold in a mold closing direction to form a cavity defined by the surface of the extrusion material and the mold; and pressurizing the resin material to fill the cavity; wherein the extrusion material has a protrusion that protrudes from the surface and is close to the storage section when the extrusion material is stored in the storage section; and during the filling, the molding pressure applied to the extrusion from the mold causes the protrusion to adhere tightly to the storage section or its periphery, thereby isolating the cavity from a gap between the inner surface of the storage section and the surface of the extrusion material.

[0008] According to the above configuration, the molding pressure applied to the extruded material during cavity formation is used to bring the protrusions on the extruded material into close contact with the mold, thereby isolating the cavity from the gap between the surface of the extruded material and the inner surface of the housing, thereby preventing the resin material from unintentionally flowing from the cavity into the gap between the extruded material and the mold.

[0009] During the filling, the molding pressure may be applied to the extruded material via the resin material.

[0010] According to the above configuration, the cavity can be isolated from the gap by utilizing the pressure applied from the resin material to the extruded material.

[0011] The extruded material may have a pair of flanges extending along the inner surface of the storage section in the stored state, the protrusions being provided in pairs on each of the pair of flanges, the pair of flanges forming an internal space between their inner surfaces, the internal space constituting part of the cavity, and during the filling, the molding pressure being applied to the pair of flanges via the resin material that has flowed into the internal space, causing the pair of flanges to bend toward the inner surface of the storage section, and the protrusions to adhere closely to the storage section or its peripheral portion.

[0012] According to the above configuration, by flowing resin material into the pair of flanges, a structure is realized in which the pressure of the resin material is used to deform the extruded material. The resin material filling the internal space is integrated with the extruded material, thereby increasing the contact area between the resin material and the extruded material, and the resin material is firmly bonded to the extruded material.

[0013] The protrusion may be provided on an outer surface of the flange, and the protrusion may be in close contact with the inner surface of the accommodating portion when the resin material is filled.

[0014] According to the above-mentioned configuration, the resin material applies pressure in the thickness direction of the flange, and the protrusion adheres closely to the housing portion along the direction of the pressure, making it easy to eliminate gaps.

[0015] The extrusion material may have an inner inclined surface provided on at least one of the tip ends of the pair of flanges, and the inner inclined surface may be inclined so as to move away from the storage portion as it moves toward the base end side of the pair of flanges in the stored state.

[0016] According to the above configuration, when the resin material flows into the internal space and acts on the inner inclined surface in the mold closing direction, the inner inclined surface is pressed in a direction toward the housing portion by the wedge action, which makes the flange more likely to bend toward the housing portion and makes it easier to close the gap.

[0017] The extrusion material may be provided at at least one of the tip ends of the pair of flanges, have a convex portion that protrudes toward the internal space beyond the inner surface of the flange, and the inner inclined surface may be formed on the convex portion.

[0018] According to the above configuration, the resin material is crimped by the convex portion, and the bonding strength of the resin material to the extruded material is improved.

[0019] The extruded material may be provided on the underside of at least one of the pair of protrusions, and have a pair of outer inclined surfaces that slope away from the storage section as the extruded material moves in the direction of storage into the storage section in the stored state, and when the extruded material is stored, the flange may bend toward the internal space due to interference between the outer inclined surfaces and the storage section, and the protrusion may be tightly attached to the inner surface of the storage section due to the elastic force of the flange.

[0020] With this configuration, the flange can be deflected inward by the wedge action of the outer inclined surface while the extruded material is being accommodated. The protrusion can be brought into close contact with the accommodation portion by utilizing the reaction force caused by the elastic deformation of the flange, and the gap can be closed more reliably.

[0021] The extruded material may have a protruding piece that protrudes outward from at least one of the tip ends of the pair of flanges and is exposed from the storage section in the storage state, the protrusion being provided at the tip end of the protruding piece, and the protrusion being in close contact with the peripheral edge of the storage section when the resin material is filled.

[0022] According to the above configuration, the gap is filled outside the storage portion, so that the amount of undesired inflow of the resin material can be reduced.

[0023] The protruding piece may have a pressure-receiving surface that is perpendicular to the opening and closing direction of the mold in the accommodated state, and the protrusion may be provided at the tip of the protruding piece and face the peripheral edge in the opening and closing direction.

[0024] With this configuration, the protruding piece is pressed against the periphery of the housing not only by the bending of the flange but also by the molding pressure acting on the protruding piece, improving the adhesion of the protrusion and enabling the gap to be filled more reliably.

[0025] The mold may further include a third mold that is movable relative to the first mold in the opening and closing direction of the mold and forms the storage section together with the first mold, the protrusion protruding in the opening and closing direction in the storage state, and the third mold contacting the protrusion may apply the molding pressure to the extruded material from the third mold.

[0026] According to the above configuration, the third mold, which can move in the opening and closing directions, also forms the housing portion, so even if the extruded material has a complex cross-sectional shape, it can be easily placed in the mold and released from the mold. In this case, the molding pressure of the third mold is applied directly to the protrusion. This generates a local surface pressure on the protrusion, causing it to adhere tightly to the housing portion. This makes it easier to close the gap.

[0027] The protrusions may be provided in pairs on both sides of the extruded material in the opening and closing direction, with one of the protrusions blocking the portion of the gap formed by the extruded material and the first mold from the cavity, and the other protrusion blocking the portion of the gap formed by the extruded material and the third mold from the cavity.

[0028] According to the above configuration, the molding pressure from the third mold can be used to close the gap in both the first mold and the second mold.

[0029] The one protrusion may protrude in a direction approaching the first die relative to a surface of the extruded material that is placed on the first die.

[0030] According to the above configuration, it becomes easier to bring one of the protrusions into close contact with the first mold by utilizing the molding pressure from the third mold, and the gap can be more reliably closed.

[0031] The other protrusion may be provided on a step portion formed in a hook shape on the extruded material, and the third mold may come into contact with the other protrusion, thereby applying the molding pressure to the other protrusion from the third mold.

[0032] According to the above configuration, the molding pressure from the third mold is used to deflect the hook-shaped step portion, thereby making it possible to bring the other protrusion into close contact with the third mold, thereby more reliably closing the gap.

[0033] A second aspect of the present invention provides an apparatus for manufacturing a metal-resin composite that integrates a resin material with a metallic extrusion material by press molding, the apparatus comprising: a mold including a first mold that forms a storage section for partially accommodating the extrusion material; and a second mold that is movable relative to the first mold; and a moving mechanism that moves the second mold, wherein the extrusion material has a protrusion that protrudes from its surface and is close to the storage section when the extrusion material is accommodated in the storage section; when the second mold is moved by the moving mechanism with the resin material placed on the first mold, a cavity is formed between the surface of the extrusion material and the mold, the resin material is pressurized and filled into the cavity, and the molding pressure applied to the extrusion from the mold causes the protrusion to adhere to the storage section or its periphery, and the cavity is isolated from the gap between the inner surface of the storage section and the surface of the extrusion. [Effects of the Invention]

[0034] According to the present invention, when a metal resin composite is manufactured by press-molding a resin material onto an extruded material, it is possible to suppress the resin material from flowing into the gap between the die and the extruded material. [Brief explanation of the drawings]

[0035] [Figure 1A] 1 is a plan view of a metal-resin composite manufactured by a manufacturing apparatus and method according to a first embodiment of the present invention. [Figure 1B] Cross-sectional view taken along the arrows BB in FIG. 1A. [Figure 2A] FIG. 1 is a cross-sectional view of a manufacturing apparatus according to a first embodiment. [Figure 2B] Cross-sectional view taken along the arrows BB in FIG. 2A. [Figure 3] FIG. 1 is a conceptual diagram of a manufacturing method according to a first embodiment. [Figure 4] 1 is a cross-sectional view of an extruded material prepared in the manufacture of a metal-resin composite according to the first embodiment. [Figure 5] FIG. 1 is a conceptual diagram of a manufacturing method according to a first embodiment. [Figure 6] FIG. 1 is a conceptual diagram of a manufacturing method according to a first embodiment. [Figure 7] A partial enlarged view of Figure 6. [Figure 8] FIG. 10 is a view corresponding to FIG. 4 in a second embodiment. [Figure 9] FIG. 10 is a view equivalent to FIG. 3 in a second embodiment. [Figure 10] FIG. 8 is a diagram corresponding to FIG. 7 in a second embodiment. [Figure 11] FIG. 11 is a cross-sectional view of a metal-resin composite manufactured by a manufacturing apparatus and method according to a third embodiment. [Figure 12] FIG. 10 is a view corresponding to FIG. 3 in a third embodiment. [Figure 13] FIG. 10 is a view corresponding to FIG. 6 in a third embodiment. [Figure 14] FIG. 10 is a view corresponding to FIG. 7 in a third embodiment. [Figure 15A] FIG. 10 is a plan view of a metal-resin composite manufactured by a manufacturing apparatus and method according to a fourth embodiment. [Figure 15B] 15B is a cross-sectional view taken along the arrow BB in FIG. 15A. [Figure 16]FIG. 10 is a cross-sectional view of an extruded material prepared in the production of a metal-resin composite according to a fourth embodiment. [Figure 17] 10A and 10B are conceptual diagrams of a manufacturing apparatus and a manufacturing method according to a fourth embodiment. [Figure 18] FIG. 10 is a conceptual diagram of a manufacturing method according to a fourth embodiment. [Figure 19] FIG. 10 is a conceptual diagram of a manufacturing method according to a fourth embodiment. [Figure 20] FIG. 10 is a conceptual diagram of a manufacturing method according to a fourth embodiment. [Figure 21] FIG. 10 is a conceptual diagram of a manufacturing method according to a fourth embodiment. [Figure 22] FIG. 15B is a view corresponding to FIG. 15B in the fifth embodiment. [Figure 23] FIG. 17 is a view corresponding to FIG. 16 in the fifth embodiment. [Figure 24] FIG. 17 is a diagram corresponding to FIG. 17 in the fifth embodiment. [Figure 25] FIG. 18 is a diagram corresponding to FIG. 18 in the fifth embodiment. [Figure 26] FIG. 19 is a view corresponding to FIG. 19 in the fifth embodiment. [Figure 27] FIG. 20 is a diagram corresponding to FIG. 20 in the fifth embodiment. [Figure 28] FIG. 21 is a diagram corresponding to FIG. 21 in the fifth embodiment. [Figure 29] FIG. 15B is a view corresponding to FIG. 15B in the fifth embodiment. [Figure 30] FIG. 17 is a view corresponding to FIG. 16 in the fifth embodiment. [Figure 31] FIG. 17 is a diagram corresponding to FIG. 17 in the fifth embodiment. [Figure 32] FIG. 18 is a diagram corresponding to FIG. 18 in the fifth embodiment. [Figure 33] FIG. 19 is a view corresponding to FIG. 19 in the fifth embodiment. [Figure 34] FIG. 20 is a diagram corresponding to FIG. 20 in the fifth embodiment. [Figure 35] FIG. 21 is a diagram corresponding to FIG. 21 in the fifth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0036] The present invention will be described with reference to the accompanying drawings, in which the same or corresponding elements are designated by the same reference numerals throughout the drawings, and redundant description will be omitted.

[0037] In the manufacturing apparatus 1 and manufacturing method for the metal-resin composite 100, a resin material 300 is integrated with a metallic extrusion material 200 by press molding using a mold 2 (see FIGS. 1A and 2A). The X direction in the drawings corresponds to the extrusion direction or longitudinal direction of the extrusion material 200. Simply referring to a "cross section" refers to a cross section perpendicular to the X direction. The Y direction is one direction within the cross section and corresponds to the width direction of the extrusion material 200. The Z direction is perpendicular to the Y direction within the cross section, corresponds to the height direction of the extrusion material 200, and also corresponds to the opening and closing direction of the mold 2. Because the Z direction is oriented vertically in some drawings, for ease of explanation, the Z direction will be defined as vertical and the XY directions as horizontal. The upward direction (+Z direction) corresponds to the mold opening direction M1, and the downward direction (-Z direction) corresponds to the mold closing direction M2. However, this is merely an example, and the orientations of the metal-resin composite 100 and its components, as well as the manufacturing apparatus 1 and its components, can be changed as appropriate.

[0038] (First embodiment) 1A and 1B, a metal resin composite 100 according to the first embodiment includes a metal extrusion material 200 and a resin material 300 provided on the extrusion material 200. The metal resin composite 100 is suitably applied to structural parts such as the body frame of an automobile.

[0039] The metal material of the extrusion material 200 is not particularly limited. Light alloys such as aluminum alloys and magnesium alloys are suitable examples of metal materials, and contribute to achieving both lightweight and high rigidity in structural components. In the following, as a mere example, the extrusion material 200 is made of an aluminum alloy.

[0040] Although detailed illustration is omitted, the extrusion material 200 is obtained by heating and compressing a billet-shaped metal material within the main body of an extrusion molding machine and then extruding it through a die attached to the main body. After being extruded from the die, required processes such as cooling, pulling, and cutting are performed. The cross section of the extrusion material 200 is determined by the shape of the die, so it is uniform in the longitudinal direction X. However, twists and bends occur due to hot forming. Each element of the extrusion material 200 extends in the longitudinal direction X and is seamlessly integrated with one another.

[0041] The resin material 300 is obtained by press-molding a compound in a manufacturing apparatus 1 (see FIGS. 2A and 2B). The compound may be a sheet-shaped SMC (sheet molding compound) or a bulk-molding compound (BMC) formed in a block. SMC or BMC is realized by fiber-reinforced plastic (FRP), in which fibers are impregnated into a matrix resin. The matrix resin contains a thermosetting resin such as unsaturated polyester as its main component, and additives are mixed into the main component. The additives include, for example, a mold release agent. The fibers are, for example, glass or carbon fibers, cut short and oriented randomly within the compound. However, the resin material 300 is not limited to a thermosetting resin and may be a thermoplastic resin. In the following description, the resin material 300 is made of SMC as a mere example.

[0042] In this embodiment, the extruded material 200 has a rectangular cross section. The long sides of the rectangle extend in the height direction Z, and the short sides extend in the width direction Y. The resin material 300 is provided on top of the extruded material 200 and is formed into a plate shape having a width greater than that of the extruded material 200. The cross section of the metal-resin composite 100 is formed in a T-shape and is line-symmetrical with respect to the center line in the width direction. The cross sections of the extruded material 200 and the resin material 300 are also line-symmetrical.

[0043] There is no particular limitation on the shape in plan view of the resin material 300. Here, as a mere example, the shape in plan view is a rectangle with long sides extending in the longitudinal direction X and short sides extending in the width direction Y, the short sides of the resin material 300 are aligned with both ends of the extruded material 200 in the longitudinal direction X, and the cross section of the metal resin composite 100 is uniform in the longitudinal direction X.

[0044] 2A and 2B, the manufacturing apparatus 1 mainly includes a mold 2, a drive unit 3, and a heating unit 4. The mold 2 includes a first mold 10 and a second mold 20. The first mold 10 is configured as a fixed mold, a lower mold, or a die. The second mold 20 is configured as a movable mold, an upper mold, or a punch. The second mold 20 is disposed above the first mold 10 (i.e., in the mold opening direction M1) and is movable in the up-down direction (i.e., the opening / closing direction) relative to the first mold 10.

[0045] The first mold 10 has a base 11 and a shoulder 12. The upper surface of the base 11 forms a horizontal lower molding surface 41. The shoulder 12 protrudes upward from the peripheral edge of the base 11, and the inner surface of the shoulder 12 extends upward from the lower molding surface 41. The inner surface of the shoulder 12 has the same shape as the resin material 300 of the metal-resin composite 100 in a cross section perpendicular to the opening / closing direction (details not shown). In this example, since the resin material 300 has a rectangular shape in a planar view (see FIG. 1A), the shoulder 12 has a rectangular window frame shape in a planar view, as can be seen in FIGS. 2A and 2B. The lower part of the inner surface of the shoulder 12 forms a vertical side molding surface 42. The upper part of the inner surface of the shoulder 12 forms a lower mating surface 14.

[0046] The first mold 10 has a storage section 15 that stores the extruded material 200. The storage section 15 is recessed in the lower molding surface 41. The storage section 15 has a U-shaped inner surface 16 and is configured as a groove that is open to the lower molding surface 41. The inner surface 16 of the storage section 15 includes a pair of inner surfaces 16a, 16b that extend downward and are continuous with the lower molding surface 41, and an inner bottom surface 16c that horizontally connects the inner surfaces 16a, 16b.

[0047] The second mold 20 has a main body 21. The main body 21 is, for example, rectangular parallelepiped-shaped. The lower surface of the main body 21 forms an upper molding surface 43 that faces the lower molding surface 41 in the opening / closing direction. The side surface of the main body 21 forms an upper mating surface 24 that extends upward from the periphery of the lower molding surface 41. In a cross section perpendicular to the opening / closing direction (details not shown), the upper mating surface 24 is similar to, but slightly smaller than, the cross section of the inner surface of the shoulder portion 12. For convenience, this distance is exaggerated in the drawings.

[0048] The driving unit 3 moves the second mold 20 in the opening and closing direction between a retracted position (see the solid line) and the bottom dead center (see the two-dot chain line).

[0049] Hereinafter, a description will be given of a method for manufacturing a metal resin composite 100 (see FIG. 1A) using the above-described manufacturing apparatus 1. In addition, the structures of the mold 2, the extrusion material 200, the resin material 300, and the metal resin composite 100 will be further described.

[0050] Referring to FIG. 3, the mold 2 is configured as described above and below and prepared in the manufacturing apparatus 1. Furthermore, a compound of the extrusion material 200 and the resin material 300 is prepared each time one metal-resin composite 100 is manufactured. The second mold 20 is positioned at the retracted position. When the second mold 20 is positioned at the retracted position, the upper molding surface 43 is spaced upwardly from the upper end surface of the first mold 10 by a sufficient distance to facilitate the placement of the extrusion material 200 and the compound and the removal of the metal-resin composite 100.

[0051] 4, the prepared extrusion material 200 has a bottom wall 201, a pair of side walls 202, 203, and an upper wall 204. The pair of side walls 202, 203 form the longer sides of the rectangular cross section and extend in the height direction Z, while the bottom wall 201 and the upper wall 204 form the shorter sides of the rectangular cross section and extend in the width direction Y. The pair of side walls 202, 203 stand upright from a pair of side edges of the bottom wall 201, respectively. The upper wall 204 connects the upper portions of the side walls 202, 203 to each other.

[0052] The extruded material 200 has a hollow 210 defined by the inner surfaces of the walls 201 to 204, and one or more partition walls 205 that separate the hollow 210. The hollow 210 is open at both ends in the longitudinal direction X. In this embodiment, there is a single partition wall 205 that connects the inner surfaces of the side walls 202, 203 to each other between the bottom wall 201 and the top wall 204 in the height direction Z, and the partition wall 205 divides the hollow 210 into a first chamber 211 and a second chamber 212 in the height direction Z. However, multiple partition walls may be arranged at intervals in the height direction Z, or the partition wall may be omitted.

[0053] The extrusion material 200 has a pair of flanges 222, 223. The pair of flanges 222, 223 are portions that extend upward from the pair of side walls 202, 203. The outer surface of the flange 222 is substantially flush with the outer surface of the side wall 202, and together with the outer surface of the side wall 202, they form the entire outer surface of the extrusion material 200. The thickness of the flange 222 is the same as, or thinner or thicker than, the thickness of the side wall 202. The relationship between the flange 223 and the side wall 203 is similar.

[0054] The extrusion material 200 has an internal space 220 defined by the outer surface (i.e., the upper surface) of the upper wall 204 and the inner surfaces of the pair of flanges 222, 223. The internal space 220 is open in both directions in the longitudinal direction X and upward. The tip ends (i.e., upper ends) of the pair of flanges 222, 223 in the height direction Z form an opening 221 of the internal space 220.

[0055] The extrusion material 200 has a pair of protrusions 224, 225 provided at the tip ends of a pair of flanges 222, 223, respectively. Each protrusion 224, 225 protrudes inward in the width direction Y from the tip end of the corresponding flange 222, 223. In other words, the protrusions 224, 225 protrude toward each other toward the internal space 220. This narrows the upper opening 221 compared to a case where the protrusions 224, 225 are not present. In addition, the lower surfaces of the protrusions 224, 225 face the internal space 220.

[0056] The extrusion material 200 has inner inclined surfaces 226, 227 provided on the tip ends of the pair of flanges 222, 223 (particularly, the pair of protrusions 224, 225 in this embodiment). The inner inclined surfaces 226, 227 connect the upper surfaces and side surfaces of the protrusions 224, 225, and are inclined inward in the width direction Y as they extend downward. The downward side as viewed from the protrusions 224, 225 corresponds to the base end side of the flanges 222, 223 and also corresponds to the mold closing direction M2. The inner side corresponds to the internal space 220 side and also corresponds to the side away from the accommodation portion 15.

[0057] The extruded material 200 has protrusions 231, 232 protruding from its surface. In this embodiment, the protrusions 231, 232 form a pair in the width direction Y. The pair of protrusions 231, 232 is provided on the outer surfaces of the pair of flanges 222, 223, respectively, and protrudes outward in the width direction Y from the pair of flanges 222, 223.

[0058] In particular, in this embodiment, a pair of protrusions 231, 232 are provided at the tip ends of the pair of flanges 222, 223, respectively. The protrusion 231 and the convex portion 224 are integrated at the tip end of the flange 222, protrude from the tip end to both sides in the width direction Y, and form a common upper surface that is wider than the plate thickness of the flange 222. The relationship between the protrusion 232, the convex portion 225, and the flange 223 is similar to this.

[0059] 3 and 4, the prepared extrusion material 200 is accommodated in the accommodation unit 15. After that, the prepared compound of the resin material 300 is placed on the first mold 10. The extrusion material 200 and the compound may be placed manually. The manufacturing apparatus 1 may include a manipulator for placing the extrusion material 200 and the compound.

[0060] The width of the storage section 15 is defined as the distance between the inner surfaces 16a and 16b in the width direction Y. The depth of the storage section 15 is defined as the length in the opening / closing direction from the lower molding surface 41 to the inner bottom surface 16c. The width of the extruded material 200 is defined as the distance between the side end surfaces of the protrusions 231 and 232 in the width direction Y. The height of the extruded material 200 is defined as the length in the height direction Z from the lower surface of the bottom wall 201 to the upper surfaces of the flanges 221 and 222 (i.e., the common upper surface of the protrusions 231 and 232 and the convex portions 224 and 225). The difference between the maximum allowable dimension and the minimum allowable dimension is defined as the dimensional tolerance. The dimensional tolerance of the extruded material 200 is set, for example, within the range of 0.5 to 1.0 mm. In addition to the dimensional tolerance, the extruded material 200 may be molded taking into consideration geometric tolerances, such as the flatness of the lower surface of the bottom wall 201 and the outer surfaces of the side walls 202 and 203. The prepared extrusion 200 is formed to within tolerances.

[0061] When the extruded material 200 is accommodated, the extruded material 200 is inserted into the accommodation portion 15 in an insertion position with the bottom wall 201 facing downward. The width of the accommodation portion 15 is the same as the maximum allowable width of the extruded material 200. Therefore, the extruded material 200 formed within the dimensional tolerance can move downward within the accommodation portion 15 without interfering with the accommodation portion 15.

[0062] Considering that the extrusion material 200 does not interfere with the accommodation portion 15 and that its own weight acts on it, it can be easily inserted until the bottom wall 201 seats on the inner bottom surface 16c. The depth of the accommodation portion 15 is greater than the maximum allowable height of the extrusion material 200. Therefore, when the extrusion material 200 is accommodated, the entire extrusion material 200 is accommodated in the accommodation portion 15, and the upper surface of the extrusion material 200 is positioned slightly below the lower molding surface 41. The side surfaces of the protrusions 231 and 232 face the upper end of the inner surface of the accommodation portion 15 with a very small clearance. Below the protrusions 231 and 232, a gap 51 is formed between the inner surface 16 of the accommodation portion 15 and the surface of the extrusion material 200 (e.g., the outer surfaces of the side walls 202 and 203 or the lower surface of the bottom wall 201).

[0063] 3, next, the mold 2 is preheated by the heating unit 4, and the temperature of the mold 2 is raised to a predetermined temperature. Next, a compound of the resin material 300 (e.g., SMC) is placed on the lower molding surface 41, and covers the extruded material 200 accommodated in the accommodation unit 15 from above.

[0064] Next, referring to Figure 5, the drive unit 3 moves the second mold 20 in the mold closing direction M2 (downward) from the retracted position to the bottom dead center. As the second mold 20 moves downward, the main body 21 fits into the shoulder 12, and the upper mating surface 24 faces the lower mating surface 14 with a small mold gap 52 between them. The second mold 20 slides downward, guided by the shoulder 12. The second mold 20 presses the resin material 300 compound downward. The compound is softened by the heat of the mold 2 and flows when pressed by the molding pressure applied by the second mold 20.

[0065] 6, when the second mold 20 is at the bottom dead center, the upper molding surface 43 and the lower molding surface 41 are spaced apart in the opening / closing direction. The lower mating surface 14 is the portion of the inner surface of the shoulder portion 12 that is above the upper molding surface 43 when the second mold 20 is at the bottom dead center. The side molding surface 42 is the portion of the inner surface of the shoulder portion 12 that is below the upper molding surface 43 when the second mold 20 is at the bottom dead center. The lower molding surface 41, the side molding surface 42, and the upper molding surface 43 define a cavity 40 that is intended to be filled with a compound.

[0066] The cavity 40 communicates with the interior of the storage section 15 formed in the lower molding surface 41, and communicates with an internal space 220 via an upper opening 221 of the extruded material 200 in the storage section 15. The internal space 220 is intended to be filled with the resin material 300. In other words, the internal space 220 constitutes a part of the cavity 40, and the cavity 40 is also defined by the surface of the extruded material 200. The cavity 40 communicates with a mold gap 52. Like the mold gap 52, the gap 51 is not intended to be filled with the resin material 300.

[0067] 7, as the second mold 20 moves downward, the resin material 300 is pressurized downward and flows into the storage portion 15 (see arrow 1). After the resin material 300 reaches the same level as the upper surface of the extruded material 200 in the opening / closing direction, the upper opening 221 and the clearances between the protrusions 231, 232 and the inner surface 16 of the storage portion 15 are assumed to be flow paths for the resin material 300. However, this clearance has a much higher inflow resistance than the upper opening 221, and therefore the resin material 300 tries to pass through the upper opening 221.

[0068] At this time, the resin material 300 applies downward pressure (see arrow 2) to the inner inclined surfaces 226, 227 based on the molding pressure (see arrow 1) applied from the second mold 20. As a result, the protrusions 224, 225 are pushed outward in the width direction Y by a wedge action, and the flanges 222, 223 are bent outward in the width direction Y (see arrow 3). Furthermore, the resin material 300 that has flowed into the internal space 220 presses the surfaces that define the internal space 220 based on the molding pressure applied from the second mold 20 (see arrow 4), thereby bending the flanges 222, 223 outward in the width direction Y (see arrow 3). However, the inner inclined surfaces 226, 227 may be omitted, and the end faces of the protrusions 224, 225 may be connected perpendicularly to the upper surface. In this case, too, it is possible to apply this molding pressure perpendicularly to the inner surface of the end portion, thereby promoting the bending deformation of flanges 222 and 223 in the direction of arrow 3.

[0069] As a result, the protrusions 231 and 232 come into close contact with the inner surfaces 16a and 16b, respectively, of the accommodation portion 15 (see arrow 3). The deformation direction of the flanges 222 and 223 is along the normal direction of the inner surfaces 16a and 16b. Therefore, by utilizing the bending of the flanges 222 and 223, the protrusions 231 and 232 can be easily brought into close contact with the inner surfaces 16a and 16b.

[0070] In this way, the gap 51 can be filled by the wedge action before the resin material 300 flows into the gap 51. This blocks the cavity 40 from the gap 51, preventing the resin material 300 from unintentionally flowing into the gap 51. Note that the mold gap 52 (see FIG. 6) is narrow and has high inflow resistance. Therefore, even if the resin material 300 flows into the mold gap 52, only a small amount of the resin material 300 flows.

[0071] Although detailed illustration is omitted, when a predetermined period of time has passed with the second mold 20 positioned at the bottom dead center, the resin material 300 hardens. After the resin material 300 has hardened, the drive unit 3 moves the second mold 20 in the mold opening direction M1 (upward) to a retracted position. Next, the metal-resin composite 100 is removed from the first mold 10.

[0072] Since the resin material 300 is prevented from flowing into the gap 51, the production efficiency of the metal-resin composite 100 is improved. In other words, since less resin material 300 hardens in the housing portion 15, the mold release resistance can be kept low. After mold release, the work of peeling off unnecessary resin material 300 from the surface of the extruded material 200 can also be simplified, and only the minimum amount of deburring is required. Since leakage of the compound is suppressed, it is easier to ensure the appropriate amount of resin material 300 in the cavity 40, improving the rate of non-defective products and yield.

[0073] 1A and 1B, the cured resin material 300 has plate portions 301 on the extruded material 200 that protrude on both sides in the width direction Y from the extruded material 200, and protrusions 302 that protrude downward from the center of the plate portion 301 in the width direction Y. The profiles of the upper molding surface 43, the side molding surface 42, and the lower molding surface 41 (see FIG. 6) are transferred to the top surface, side surfaces, and bottom surface of the plate portion 301, respectively.

[0074] The protruding portion 302 is provided on the projections 231, 232 that contribute to closing the gap 51 (see FIG. 6) in appearance. The protruding portion 302 fills the internal space 220 and contacts the lower surfaces of the convex portions 224, 225. Since the resin material 300 is crimped to the extruded material 200, the bonding strength of the resin material 300 to the extruded material 200 is improved.

[0075] The region between the pair of flanges 222, 223 is solid with resin material 300 and has high strength. This allows the flanges 222, 223 to be made thinner to improve flexibility. This makes it easier to fill the gap 51 (see FIG. 7) while ensuring the strength of the metal-resin composite body 100.

[0076] Furthermore, the upper surfaces of the flanges 222, 223 are made wider than the plate thickness of the flanges 222, 223 due to the integration of the convex portions 223, 224 and the protrusions 231, 232. This ensures as large a contact area as possible between the extruded material 200 and the resin material 300. This not only makes it possible to reduce unnecessary resin material 300 by filling the gap 51 (see FIG. 7) at the upper end of the accommodation section 15, but also maintains high bonding strength between the resin material 300 and the extruded material 200.

[0077] (Second embodiment) The second embodiment will be described below, focusing on the differences from the above embodiment.

[0078] 8, the extrusion material 200 further has outer inclined surfaces 233, 234 provided on the lower surfaces of the protrusions 231, 232. The outer inclined surfaces 233, 234 connect the side surfaces of the protrusions 231, 232 to the outer surfaces of the flanges 222, 223, and are inclined downward as they extend inward in the width direction Y.

[0079] The relationship between the depth of the accommodating portion 15 and the height of the extruded material 200 is the same as in the first embodiment. The width of the accommodating portion 15 is smaller than the maximum allowable width of the extruded material 200. That is, the accommodating portion 15 may interfere with the extruded material 200, which is molded within the dimensional tolerances, in terms of design.

[0080] The width of the accommodating portion 15 may be smaller than the minimum allowable width of the extruded material 200. In this case, the accommodating portion 15 will interfere with any of the extruded materials 200 molded within the dimensional tolerances, as designed. The width of the accommodating portion 15 may be set between the maximum allowable width and the minimum allowable width of the extruded material 200, and may be equal to the reference width dimension, for example. When the width of the extruded material 200 is smaller than the reference dimension, the extruded material 200 is inserted into the accommodating portion 15 without interfering with the accommodating portion 15, as in the first embodiment.

[0081] Referring to FIG. 9 , when the width of the extruded material 200 is greater than the width of the storage section 15, when the storage section 15 is inserted into the storage section 15 from above in the insertion position, substantially the entire extruded material 200 is inserted into the storage section 15 without interfering with the storage section 15. Just before the insertion is completed, the outer inclined surface 233 abuts against the corner between the inner surface 16 a of the storage section 15 and the lower molding surface 41, and the outer inclined surface 234 abuts against the corner between the inner surface 16 b of the storage section 15 and the lower molding surface 41. When further downward force is applied to the extruded material 200, the protrusions 222 and 223 move inward in the width direction Y due to the wedge action, and the flanges 222 and 223 are flexibly deformed inward in the width direction Y. This allows the extruded material 200 to move downward relative to the first mold 10. The extruded material 200 moves downward until the bottom wall 201 seats on the inner bottom surface 16 c of the storage section 15.

[0082] 10, the deformation of the flanges 222, 223 remains within the elastic range. The flanges 222, 223 exert a reaction force due to elastic deformation outward in the width direction Y (toward the inner surface of the storage section 15) in an attempt to restore their original shape (see arrow 5). This reaction force presses the side surfaces of the protrusions 231, 232 against the inner surfaces 16a, 16b of the storage section 15, and they come into close contact with the inner surfaces 16a, 16b (see arrow 3).

[0083] Thereafter, similarly to the first embodiment shown in FIGS. 5 and 6, a compound of the resin material 300 is placed in the first mold 10 and pressed at high temperature and high pressure. In this embodiment, the gaps 51 are already filled before the resin material 300 is press-molded. This more reliably prevents the resin material 300 from flowing into the gaps 51. Furthermore, similarly to the first embodiment, the flanges 222 and 223 are pressed outward in the width direction Y based on the molding pressure applied from the resin material 300 to the inner inclined surfaces 226 and 227 and the inner surfaces of the flanges 222 and 223 (see arrows 1 to 4 in FIG. 10). This further improves the sealing performance of the cavity 40.

[0084] Since the protrusions 231, 232 are in close contact with the inner surface 16 of the housing portion 15 due to the reaction force caused by the elastic deformation of the flanges 222, 223, the mold release resistance may be slightly higher than in the first embodiment, but the hardening of the resin material 300 in the gap 51 can be more reliably prevented. Therefore, the production efficiency of the metal resin composite 100 is high, similar to that of the first embodiment.

[0085] (Third embodiment) The third embodiment will be described below, focusing on the differences from the above-described embodiments.

[0086] 11, the extruded material 200 has a pair of protruding pieces 235, 236 that protrude outward in the width direction Y from the tip ends of the pair of flanges 222, 223, respectively. The pair of protruding pieces 235, 236 are formed in the shape of flat plates that extend perpendicularly from the flanges 222, 223. A pair of projections 231, 232 are provided at the tip ends of the pair of protruding pieces 235, 236, respectively. Each projection 231, 232 protrudes downward from the corresponding protruding piece 235, 236. In this way, the projections 231, 232 are provided on the outer surfaces of the flanges 222, 223 via the protruding pieces 235, 236.

[0087] Each of the protruding pieces 235, 236 is integrated with the protruding portions 224, 225 at the tip of the corresponding flange 222, 223 to form a common upper surface. Note that, although the present embodiment illustrates a case in which the protruding portions 224, 225 do not have the inner inclined surfaces 226, 227 (see FIG. 4), the protruding portions 224, 225 may have the inner inclined surfaces 226, 227 as in the first embodiment.

[0088] 12, the width of the accommodation portion 15 is greater than the maximum allowable dimension of the gap between the outer surfaces of the side walls 202, 203. The depth of the accommodation portion 15 is smaller than the minimum allowable dimension of the length from the lower surface of the bottom wall 201 to the lower surfaces of the protrusions 235, 236, and is also smaller than the minimum allowable dimension of the length from the lower surface of the bottom wall 201 to the lower surfaces of the protrusions. As a result, the extrusion material 200 can be inserted downward into the accommodation portion 15 without interfering with the accommodation portion 15 until the bottom wall 201 seats on the inner bottom surface 16c of the accommodation portion 15, as in the first embodiment.

[0089] In this stored state of the extruded material 200, the upper portion of the extruded material 200 protrudes upward relative to the storage section 15 or the lower molding surface 41. In particular, in this embodiment, based on the above-mentioned dimensional relationship, not only the protruding pieces 235, 236 but also the protrusions 231, 232 do not interfere with the lower molding surface 41. The protruding pieces 235, 236 extend above the lower molding surface 41 in the width direction Y, and the lower surfaces of the protrusions 231, 232 face the lower molding surface 41 with a slight clearance in the opening / closing direction. The resin material 300 compound may be placed on the protruding pieces 235, 236.

[0090] 13 and 14, when second mold 20 moves downward, molding pressure acts downward on upper surfaces 235a, 236a of protruding pieces 235, 236 via resin material 300 (see arrow 6). Upper surfaces 235a, 236a function as pressure-receiving surfaces that receive the molding pressure. Protruding pieces 235, 236 are bent downward, and protrusions 231, 232 come into close contact with the peripheral edge of accommodation section 15 on lower molding surface 41 (see arrow 3).

[0091] In this embodiment, as in the first and second embodiments, molding pressure acts on the inner surfaces of the flanges 222, 223 outward in the width direction Y via the resin material 300 that has flowed into the internal space 220 (see arrow 4). The flanges 222, 223 tend to bend outward in the width direction Y around their base ends (near the portion where the upper wall 204 is provided), thereby causing the protrusions 231, 232 to move downward (see arrow 7). This action increases the degree of contact between the protrusions 231, 232 and the peripheral edge of the accommodation portion 15 (see arrow 3).

[0092] The protrusions 231, 232 are in close contact with the outside of the accommodating portion 15 rather than the inside of the accommodating portion 15, thereby isolating the cavity 40 from the gap 51. This prevents the resin material 300 from hardening inside the accommodating portion 15 and outside the extruded material 200, further reducing the mold release resistance.

[0093] Although not shown in detail, the depth of the accommodation portion 15 may be greater than the minimum allowable length from the lower surface of the bottom wall 201 to the lower surfaces of the protrusions 231 and 232. In this case, even if the extrusion material 200 is molded within the dimensional tolerance, the length from the lower surface of the bottom wall 201 to the lower surfaces of the protrusions 231 and 232 may be smaller than the depth of the accommodation portion 15. In such a case, the lower surfaces of the protrusions 231 and 232 abut against the lower molding surface 41 before the bottom wall 201 seats on the inner bottom surface 16c. As the extrusion material 200 moves further downward, the protruding pieces 235 and 236 flex and deform. When the extrusion material 200 is accommodated, the protrusions 231 and 232 adhere to the peripheral edge of the accommodation portion 15. This blocks the cavity 40 from the gap 51 before the resin material 300 is pressurized, thereby more reliably preventing the resin material 300 from flowing into the gap 51.

[0094] (Fourth embodiment) The fourth embodiment will be described below, focusing on the differences from the above-described embodiments.

[0095] 15A and 15B, metal resin composite 100 has a rectangular frame-shaped frame portion 101 and a bottom plate portion 102 that closes the lower surface of frame portion 101, and is formed into a rectangular box shape as a whole. Resin material 300 forms bottom plate portion 102 and also forms the inner surface of frame portion 101. The framework of frame portion 101 is formed by joining four extrusion members 200 into a rectangular frame shape.

[0096] Referring also to FIG. 16 , the extruded member 200 includes a bottom wall 201, a pair of side walls 202 and 203, a top wall 204, and a partition wall 205, similar to the above-described embodiment. However, the extruded member 200 does not include flanges 221 and 222. The extruded member 200 has an L-shaped cross section overall. The bottom wall 201 and the partition wall 205 extend outward in the width direction Y. Here, "outward" refers to the side opposite the inner side of the rectangular box-shaped frame portion 101. The extruded member 200 includes an outer wall 206 connecting the extended portions of the bottom wall 201 and the partition wall 205 in the height direction Z. The hollow portion 210 includes a third chamber 213 surrounded by the extended portions of the bottom wall portion 201 and the partition wall 205, the lower portion of the side wall 203, and the outer wall 206. The resin material 300 is layered on the outer surface of the side wall 202 and forms the inner surface of the frame portion 101. The extruded material 200 further has protrusions 231 and 232. The protrusion 231 is provided on the upper part of the extruded material 200, and the protrusion 232 is provided on the lower part of the extruded material 200. However, the third chamber 213 and the outer wall 206 may be omitted, and the bottom wall 201 and the partition wall 205 may not extend from the side wall 203.

[0097] In this embodiment, protrusion 231 is provided at the corner between side wall 202 and top wall 204 and protrudes upward from the corner. Protrusion 232 is provided at the corner between side wall 202 and bottom wall 201 and protrudes downward from the corner. Protrusions 231, 232 have a wedge-shaped cross section. Protrusion 231 has a pair of side surfaces and a top surface, and the side surfaces on the outer sides in the width direction are inclined. Protrusion 232 has a pair of side surfaces and a top surface, and the side surfaces on the outer sides in the width direction are inclined.

[0098] Referring to Figure 17, the mold 2 includes a third mold 30 in addition to a first mold 10 and a second mold 20. The shoulder portion 12 is omitted from the first mold 10. The upper surface of the base 11 forms a lower molding surface 41, an extrusion material mounting surface 16d, and a bottom mating surface 17. The lower molding surface 41 is formed in the center of the upper surface. The extrusion material mounting surface 16d is formed in the shape of a rectangular frame that surrounds the lower molding surface 41. The bottom mating surface 17 is formed in the shape of a rectangular frame that surrounds the extrusion material mounting surface 16d.

[0099] The second mold 20 has a main body portion 21 and a molding portion 22. The molding portion 22 is a rectangular parallelepiped that is smaller in size than the main body portion 21 and protrudes downward from the main body portion 21. The bottom surface of the molding portion 22 forms a first upper molding surface 44. The four side surfaces of the molding portion 22 form an inner molding surface 45. A rectangular frame-shaped step surface between the molding portion 22 and the main body portion 21 forms a second upper molding surface 46. The four side surfaces of the main body portion 21 form a first upper mating surface 24.

[0100] The third mold 30 is configured as a movable mold or upper mold. The third mold 30 is formed in a rectangular frame shape and slides relative to the second mold 20. The outer edge of the lower surface of the third mold 30 forms a bottom mating surface 35. The third mold 30 has a recess 31 recessed upward on its lower surface and forming the storage section 16 together with the first mold 10. The recess 31 is formed in a mortar or L-shape and gradually deepens from the outer edge. The recess 31 is defined by a first inner surface 31a, a first inner bottom surface 31b, a second inner surface 31c, and a second inner bottom surface 31d. The first inner surface 31a extends upward from the inner peripheral edge of the bottom mating surface 35. The first inner bottom surface 31b extends horizontally from the upper end of the first inner surface 31a toward the inside of the third mold 30. The second inner surface 31c extends upward from the inner peripheral edge of the first inner bottom surface 31b. The second inner bottom surface 31d extends horizontally from the upper end of the second inner surface 31c toward the inside of the third mold 30 and is continuous with the inner surface of the third mold 30. The inner surface of the third mold 30 forms a second upper mating surface 34.

[0101] In this embodiment, as shown in FIG. 17, the extruded material 200 is placed on the extruded material placement surface 16d of the first mold 10 with the second mold 20 and the third mold 30 retracted upward. Next, as shown in FIG. 18, a resin material 300 compound is placed on the lower molding surface 41, and the third mold 30 is moved downward. As a result, the extruded material 200 is accommodated in the accommodation section 15 surrounded by the recess 31 and the extruded material placement surface 16d. In this accommodated state, molding pressure is applied to the extruded material 200 from the third mold 30 (see the outline arrow). As a result, the protrusion 231 comes into close contact with the second inner bottom surface 31d of the third mold 30, and the protrusion 232 comes into close contact with the extruded material placement surface 16d of the first mold 10 (see the outline arrow). Even if the extruded material 200 is bent or twisted, the extruded material 200 is elastically deformed by the molding pressure and corrected, and the protrusions 231, 232 are pressed against the molds 10, 30 over the entire length in the longitudinal direction X.

[0102] Once the extruded material 200 is held by the first mold 10 and the third mold 30, the second mold 20 is moved downward to bottom dead center, as shown in FIGS. 19 and 20. The second mold 20 slides downward, guided by the third mold 30. The cavity 40 is defined by the lower molding surface 41, the first upper molding surface 43, the inner molding surface, the second upper molding surface, and the outer surface of the side wall 202 of the extruded material 200. Due to the close contact of the protrusions 231, 232, the cavity 40 is isolated from the gap 51 between the surface of the extruded material 200 and the inner surface of the housing portion 15 (the extruded material mounting surface 16d, the first inner lateral surface 31a, the first inner bottom surface 31b, the second inner lateral surface 31c, and the second inner bottom surface 31d).

[0103] Therefore, in this embodiment as well, when the resin material 300 is filled into the cavity 40, it is possible to prevent the resin material 300 from unintentionally flowing into the gap 51. After molding, the second mold 20 and the third mold 30 are retracted upward as shown in Fig. 21. The extruded material 200 has an outer wall, which allows it to be easily released from the mold even if it has a complex cross-sectional shape.

[0104] (Fifth embodiment) Next, a fifth embodiment will be described, focusing on the differences from the above embodiments.

[0105] 21, similarly to the fourth embodiment, metal-resin composite 100 has a frame portion 101 and a bottom plate portion 102, and the skeleton of frame portion 101 is formed by joining four extrusion members 200 into a rectangular frame shape. Resin material 300 forms not only the inner surfaces of bottom plate portion 102 and frame portion 101, but also the upper surface of frame portion 101. Accordingly, the shapes of second mold 20, third mold 30, and cavity 40 are different from those of the fourth embodiment.

[0106] 22, the extrusion material 200 is formed in an L-shape similar to the fourth embodiment, and has protrusions 231 and 232. The protrusion 231 protrudes upward from the corner between the top wall 204 and the side wall 203. The protrusion 232 protrudes inward in the width direction from the corner between the bottom wall 201 and the side wall 202. The lower surface of the protrusion 232 is positioned slightly lower than the lower surface of the bottom wall 201 (the surface to be placed on the first mold 10).

[0107] 24, the second inner bottom surface 31d of the third mold 30 has a width equivalent to that of the top wall 204 in the fourth embodiment, whereas in this embodiment, it has a width equivalent to the thickness of the side wall 203. The extrusion material 200 is placed on the extrusion material placement surface 16d of the first mold 10 with the second mold 20 and the third mold 30 retracted upward.

[0108] Next, referring to FIG. 25 , the third mold 30 is moved downward. As a result, the extruded material 200 is partially accommodated in the accommodation portion 15 surrounded by the extruded material placement surface 16d and the recess 31. The upper wall 204 and the side wall 202 are exposed from the accommodation portion 15. At this time, the molding pressure of the third mold 30 causes the protrusion 231 to adhere closely to the second inner bottom surface. The protrusion 232 is elastically deformed by the molding pressure and adheres closely to the lower molding surface 41 or the extruded material placement surface 16d. Next, a compound of the resin material 300 is placed on the lower molding surface 41.

[0109] 26 and 27, the second mold 20 is moved to the bottom dead center. The cavity 40 is defined by the lower molding surface 41, the first upper molding surface 43, the inner molding surface 45, the second upper molding surface 46, the outer surface of the side wall 202 of the extruded material 200, and the outer surface of the top wall 204 of the extruded material 200. The close contact of the protrusions 231, 232 blocks the cavity 40 from a gap 51 between the surface of the extruded material 200 and the inner surface of the housing portion 15 (the extruded material mounting surface 16d, the first inner side surface 31a, the first inner bottom surface 31b, and the second inner side surface 31c).

[0110] Therefore, also in this embodiment, when the resin material 300 is filled into the cavity 40, it is possible to prevent the resin material 300 from unintentionally flowing into the gap 51. Furthermore, referring to Fig. 28, the metal resin composite 100 can be easily released from the mold.

[0111] (Sixth embodiment) Next, a sixth embodiment will be described, focusing on the differences from the above embodiments.

[0112] 29, similarly to the fourth and fifth embodiments, metal-resin composite 100 has a frame portion 101 and a bottom plate portion 102, and the skeleton of frame portion 101 is formed by joining four extrusion members 200 into a rectangular frame shape. Resin material 300 forms the inner surfaces of bottom plate portion 102 and frame portion 101, and also forms part of the upper surface of frame portion 101. Accordingly, the shapes of second mold 20, third mold 30, and cavity 40 are different from those of the fourth embodiment.

[0113] Referring to FIG. 30 , the upper wall 204 of the extruded material 200 is higher on the outer side in the width direction than on the inner side. The upper wall 204 has a low portion 204a extending inward in the width direction Y from the upper end of the side wall 202 and a high portion 204b extending outward in the width direction Y from the upper end of the side wall 203. The extruded material 200 has a step portion 204c connecting the low portion 204a and the high portion 204b in the height direction. The protrusion 232 is the same as in the fifth embodiment. The protrusion 231 is provided on the step portion 204c and protrudes outward in the width direction Y from the corner between the high portion 204b and the step portion 204c. This forms the protrusion 231 and the step portion 204c into a hook shape.

[0114] 31, the second inner bottom surface 31d of the third mold 30 has a width equivalent to that of the upper wall 204 in the fourth embodiment, whereas in the present embodiment, it has a width equivalent to the sum of the widths of the high portion 204b and the protrusion 231. The extrusion material 200 is placed on the extrusion material placement surface 16d of the first mold 10 with the second mold 20 and the third mold 30 retracted upward.

[0115] Next, as shown in FIG. 32, the third mold 30 is moved downward. As a result, the extruded material 200 is partially accommodated in the accommodation space 15 surrounded by the extruded material placement surface 16d and the recess 31. The lower portion 204a of the upper wall 204 and the side wall 202 are exposed from the accommodation space 15. At this time, the molding pressure of the third mold 30 causes the protrusion 231 to adhere closely to the second inner bottom surface. Because the protrusion 231 is formed in a hook shape, it elastically deforms under the molding pressure and adheres closely to the third mold 30 due to the reaction force. The protrusion 232 also adheres closely to the lower molding surface 41 or the extruded material placement surface 16d, as in the fifth embodiment. Next, a compound of the resin material 300 is placed on the lower molding surface 41.

[0116] 33 and 34, the second mold 20 is moved to the bottom dead center. The cavity 40 is defined by the lower molding surface 41, the first upper molding surface 43, the inner molding surface 45, the second upper molding surface 46, the outer surface of the side wall 202 of the extruded material 200, and the outer surface of the lower portion 204a of the upper wall 204 of the extruded material 200. The close contact of the protrusions 231, 232 blocks the cavity 40 from a gap 51 between the surface of the extruded material 200 and the inner surface of the accommodation portion 15 (the extruded material mounting surface 16d, the first inner side surface 31a, the first inner bottom surface, and the second inner side surface).

[0117] Therefore, also in this embodiment, when the resin material 300 is filled into the cavity 40, it is possible to prevent the resin material 300 from unintentionally flowing into the gap 51. Furthermore, referring to Fig. 35, the metal resin composite 100 can be easily released from the mold.

[0118] The embodiments of the present invention have been described above, but the above configurations can be appropriately changed, added, or deleted within the scope of the spirit of the present invention. [Explanation of symbols]

[0119] 1 Manufacturing equipment 2. Mold 3 Drive unit 4 Heating section 10 First mold 20 Second mold 30 Third mold 200 extrusions 201 Bottom wall 202,203 side wall 204 Upper Wall 205 Partition Wall 210 Hollow 211 Room 1 212 Room 2 220 Inner Space 221 Upper opening 222,223 Flanges 224,225 Convex part 226,227 Inner inclined surface 231,232 protrusions 233,234 Outer slope

Claims

1. A method for manufacturing a metal-resin composite in which a resin material is integrated with a metal extrusion material by press molding, preparing a mold including a first mold forming a housing portion that houses at least a portion of the extruded material, and a second mold that is movable in an opening and closing direction relative to the first mold; storing the extruded material in the storage portion and placing the resin material on the first mold; moving the second mold in a mold closing direction to form a cavity defined by the surface of the extruded material and the mold, and pressurizing the resin material to fill the cavity; Equipped with the extruded material has a protrusion that protrudes from the surface and is close to the accommodation portion when the extruded material is accommodated in the accommodation portion, During the filling, the molding pressure applied to the extruded material from the mold causes the protrusion to adhere tightly to the receiving portion or its periphery, thereby isolating the cavity from a gap between the inner surface of the receiving portion and the surface of the extruded material. Method for manufacturing metal-resin composites.

2. In the filling, the molding pressure is applied to the extruded material via the resin material. The method for producing the metal-resin composite according to claim 1 .

3. the extrusion member has a pair of flanges extending along the inner surface of the housing portion in the housed state, The projections are provided in pairs on each of the pair of flanges, The pair of flanges form an internal space between their inner surfaces, and the internal space constitutes a part of the cavity, During the filling, the molding pressure is applied to the pair of flanges via the resin material that has flowed into the internal space, causing the pair of flanges to bend toward the inner surface of the accommodating portion, and the protrusions to come into close contact with the accommodating portion or its peripheral portion. The method for producing a metal-resin composite according to claim 2 .

4. the protrusion is provided on the outer surface of the flange, When the resin material is filled, the protrusion is in close contact with the inner surface of the accommodation portion. The method for producing a metal-resin composite according to claim 3 .

5. the extrusion member has an inner inclined surface provided on at least one of the tip ends of the pair of flanges, The inner inclined surface is inclined so as to move away from the housing portion toward the base end side of the pair of flanges in the housed state. The method for producing a metal-resin composite according to claim 4.

6. the extrusion member is provided on at least one of the tip ends of the pair of flanges and has a protrusion that protrudes toward the internal space beyond the inner surface of the flange, The inner inclined surface is formed on the convex portion. The method for producing a metal-resin composite according to claim 5 .

7. the extrusion member has a protruding piece that protrudes outward from at least one of the tip ends of the pair of flanges and is exposed from the accommodation portion in the accommodation state, the protrusion is provided at the tip of the protruding piece, When the resin material is filled, the protrusion is in close contact with the peripheral edge of the accommodation portion. The method for producing a metal-resin composite according to claim 3 .

8. the protruding piece has a pressure-receiving surface that is perpendicular to the opening and closing direction of the mold in the accommodated state, the protrusion is provided at the tip of the protruding piece and faces the peripheral edge in the opening and closing direction; The method for producing a metal-resin composite according to claim 7.

9. the mold further includes a third mold that is movable relative to the first mold in an opening / closing direction of the mold and forms the storage portion together with the first mold, The protrusion protrudes in the opening and closing direction in the accommodated state, and the third die comes into contact with the protrusion, and the molding pressure is applied from the third die to the extruded material. The method for producing the metal-resin composite according to claim 1 .

10. the protrusions are provided in pairs on both sides of the extruded material in the opening and closing direction, one of the protrusions blocks a portion of the gap formed by the extruded material and the first mold from the cavity, and the other of the protrusions blocks a portion of the gap formed by the extruded material and the third mold from the cavity. The method for producing a metal-resin composite according to claim 9.

11. the one protrusion protrudes in a direction approaching the first die relative to a surface of the extruded material that is placed on the first die; The method for producing a metal-resin composite according to claim 10.

12. the other protrusion is provided on a step portion of the extruded material and has a hook shape, and the third die comes into contact with the other protrusion, and the molding pressure is applied from the third die to the other protrusion. The method for producing a metal-resin composite according to claim 10 or 11.

13. A metal-resin composite manufacturing apparatus that integrates a resin material with a metal extrusion material by press molding, a mold including a first mold forming a receiving portion for partially receiving the extruded material, and a second mold movable relative to the first mold; a movement mechanism that moves the second mold; Equipped with the extruded material has a protrusion that protrudes from a surface thereof and is adjacent to the accommodation portion when the extruded material is accommodated in the accommodation portion, When the second mold is moved by the movement mechanism with the resin material placed on the first mold, a cavity defined by the surface of the extruded material and the mold is formed, the resin material is pressurized and filled into the cavity, and the molding pressure applied to the extruded material from the mold causes the protrusion to adhere tightly to the containing portion or its periphery, and the cavity is isolated from the gap between the inner surface of the containing portion and the surface of the extruded material. Metal-resin composite manufacturing equipment.

Images