METHOD FOR MANUFACTURING METAL RESIN COMPOSITES

Abstract

To provide an apparatus and method for producing a metal-resin composite that can suppress leakage of resin material to unintended locations.SOLUTION: An apparatus 50 of the present invention is for press-molding a metal plate 10 and a resin material 20 to produce a metal-resin composite 1. The device 50 comprises an upper mold 110 and a lower mold 120 that sandwich the metal plate 10 and the resin material 20, and an elastic member 124 attached to the molding surface of the lower mold 120. The upper mold 110 and the lower mold 120 provide a cavity C in which the resin material 20 is placed. The elastic member 124 is arranged so as to seal the resin material 20 in the cavity C by pressing the metal plate 10 against the upper mold 110.SELECTED DRAWING: Figure 5

Description

[Technical Field]

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

[0002] BACKGROUND ART 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). [Prior art documents] [Patent documents]

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

[0004] When press-molding a metal-resin composite, it is more difficult to close the gap between the upper and lower dies than when press-molding only a resin material. As a result, there is a risk that the resin material will leak into unintended locations through the gap between the upper and lower dies of the mold. Such resin leakage can lead to problems such as poor spot welding in the subsequent assembly process, mold sticking due to resin flow into other gaps in the mold, or insufficient resin filling pressure.

[0005] An object of the present invention is to prevent leakage of resin material to unintended locations in an apparatus and method for producing a metal-resin composite. [Means for solving the problem]

[0006] A first aspect of the present invention is An apparatus for producing a metal-resin composite by press-molding a metal member and a resin material, an upper mold and a lower mold that sandwich the metal member and the resin material; an elastic member attached to the molding surface of the lower mold; Equipped with a cavity for disposing the resin material therein is formed by the upper mold and the lower mold; The elastic member is arranged to press the metal member against the upper mold to seal the resin material in the cavity.

[0007] According to this configuration, the metal member is pressed against the upper mold by the elastic member, sealing the resin material in the cavity. This prevents the resin material from leaking out of the cavity and into unintended locations. By preventing the resin material from leaking out, the filling pressure of the resin material in the cavity increases, enabling stable molding of the resin material. This allows the production of metal-resin composites with stable quality.

[0008] The metal-resin composite may have, in a cross section perpendicular to the longitudinal direction, a bottom wall portion extending horizontally, side wall portions rising from both ends of the bottom wall portion, and flange portions extending horizontally outward from the side wall portions, The upper mold may have, in the cross section, a first molding upper surface that molds the bottom wall portion, a second molding upper surface that molds the side wall portion, and a third molding upper surface that molds the flange portion, The lower mold may have, in the cross section, a first molding lower surface that molds the bottom wall portion, a second molding lower surface that molds the side wall portion, and a third molding lower surface that molds the flange portion.

[0009] According to this configuration, the cross section of the metal-resin composite is formed into a hat shape. The hat-shaped metal-resin composite is highly versatile and can be used for a variety of purposes.

[0010] The second molded upper surface may be provided with a step.

[0011] This configuration prevents the resin material from leaking out of the cavity because it must flow over the step in the upper mold, thereby increasing the filling pressure of the resin material in the cavity and improving quality.

[0012] The second molded lower surface may be provided with a holding groove for holding the elastic member, The thickness of the elastic member may be greater than the depth of the holding groove.

[0013] With this configuration, the elastic member can be held by the holding groove, making it easy to position the elastic member and restricting its movement during molding. Furthermore, because the elastic member protrudes from the lower surface of the second molding die, it is sandwiched between the upper die (more specifically, the metal member) and the lower die and receives a compressive force. This improves the effectiveness of the sealing function of the elastic member.

[0014] The holding groove may have a shape in which the bottom is wider than the opening in the cross section.

[0015] With this configuration, the elastic member is caught in the retaining groove, preventing the elastic member from coming out of the retaining groove. During press molding, the elastic member is subjected to pressure and deforms to fit the shape of the retaining groove, so the effect of preventing the elastic member from coming out can be achieved regardless of the shape of the elastic member.

[0016] The holding groove may be disposed at the same height as the step or at a higher height than the step when the upper mold and the lower mold are closed in the cross section.

[0017] According to this configuration, the metal member is pressed against the upper mold by the elastic member at the same height as the step or at a higher position than the step, thereby sealing the resin material at a position lower than the step. This further prevents the resin material from flowing over the step in the upper mold, further increasing the filling pressure of the resin material in the cavity and improving quality. Here, "the holding groove is located at the same height as the step" means that the holding groove and the step are positioned so as to overlap in the vertical direction. Furthermore, "the holding groove is positioned higher than the step" means that the holding groove and the step are not positioned so as to overlap in the vertical direction (vertical direction), and the holding groove is positioned above the step.

[0018] The elastic member may have a chamfered or rounded shape at the end protruding from the holding groove in the cross section.

[0019] This configuration prevents the end portion protruding from the holding groove from deforming and spreading along the lower surface of the second molding die, thereby preventing it from being unintentionally pinched between the metal member and the lower die. This prevents damage to the elastic member or die seizure (abnormal wear). Specifically, it prevents die seizure (abnormal wear) caused by excessive compression force between the upper die and the metal member.

[0020] The elastic member may have a chamfered or rounded cross section at an end that is inserted into the holding groove.

[0021] This configuration ensures that the elastic member has enough room to deform within the holding groove. If the elastic member does not have enough room to deform, it may be subjected to extremely high pressure, which could result in mold seizing. Specifically, this configuration can prevent mold seizing (abnormal wear) caused by excessive compression force between the upper mold and the metal member.

[0022] A second aspect of the present invention is A method for producing a metal-resin composite by press-molding a metal member and a resin material, comprising: sandwiching the metal member and the resin material between an upper mold and a lower mold; the metal member is pressed against the upper mold via an elastic member by the sandwiching, thereby sealing a cavity formed by the upper mold and the lower mold; The metal member and the resin material are integrated by the press molding while the resin material is sealed in the cavity. The present invention provides a method for detecting a temperature difference between a plurality of electrodes.

[0023] According to this method, the metal member is pressed against the upper mold by the elastic member, sealing the resin material in the cavity. This prevents the resin material from leaking out of the cavity and into unintended locations. By preventing the resin material from leaking out, the filling pressure of the resin material in the cavity increases, enabling stable molding of the resin material. This allows the production of metal-resin composites with stable quality.

[0024] The method may further include press-molding only the metal member into a hat shape before integrating the metal member and the resin material by press-molding.

[0025] This method allows for improved molding accuracy because the metal member is press-molded independently. Furthermore, the hat-shaped metal-resin composite is highly versatile and can be used for a variety of purposes. [Effects of the Invention]

[0026] According to the present invention, in an apparatus and method for producing a metal-resin composite, leakage of resin material to unintended locations can be suppressed. [Brief explanation of the drawings]

[0027] [Figure 1] FIG. [Figure 2] FIG. 3 is a cross-sectional view showing a first step of the method for producing a metal-resin composite according to the first embodiment. [Figure 3] FIG. 4 is a cross-sectional view showing a second step of the method for producing a metal-resin composite according to the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing a third step of the method for producing a metal-resin composite according to the first embodiment. [Figure 5] FIG. 4 is a cross-sectional view showing a fourth step of the method for producing a metal-resin composite according to the first embodiment. [Figure 6] FIG. 4 is a cross-sectional view showing a fifth step of the method for producing a metal-resin composite according to the first embodiment. [Figure 7]FIG. 7 is an enlarged cross-sectional view showing a portion VII circled by a dashed line in FIG. 6. [Figure 8] FIG. 8 is a cross-sectional view showing a first modified example of FIG. 7. [Figure 9] FIG. 8 is a cross-sectional view showing a second modified example of FIG. 7. [Figure 10] FIG. 8 is a cross-sectional view showing a third modified example of FIG. 7. [Figure 11] FIG. 8 is a cross-sectional view showing a fourth modified example of FIG. 7. [Figure 12] FIG. 8 is a cross-sectional view showing a fifth modified example of FIG. 7. [Figure 13] FIG. 8 is a cross-sectional view showing a sixth modified example of FIG. 7. [Figure 14] FIG. 8 is a cross-sectional view showing a seventh modified example of FIG. [Figure 15] FIG. 10 is a cross-sectional view showing a fifth step of the method for producing a metal-resin composite according to the second embodiment. [Figure 16] FIG. 10 is a cross-sectional view showing a second step of the method for manufacturing a metal-resin composite according to another modified example. DETAILED DESCRIPTION OF THE INVENTION

[0028] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An apparatus and method for manufacturing a metal-resin composite body according to an embodiment of the present invention will now be described with reference to the accompanying drawings.

[0029] (First embodiment) Referring to Fig. 1, the metal resin composite 1 produced in this embodiment includes a metal plate (metal member) 10 and a resin material 20. The metal resin composite 1 has a hat shape in a cross section perpendicular to the longitudinal direction. Specifically, 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.

[0030] The metal-resin composite 1 has a bottom wall 2 extending horizontally, 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 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 only of the metal plate 10. Partway along the side wall 3 from the bottom wall 2 toward the flange 4, the resin material 20 terminates at an end surface 20a.

[0031] 2 to 6, an apparatus 50 and a method for manufacturing a metal resin composite 1 according to this embodiment will be described. In the drawings, the horizontal direction is indicated as the X direction, and the vertical direction (up-down direction or height direction) is indicated as the Y direction. The metal resin composite 1 (metal plate 10 and resin material 20) and an elastic member 124 (described later) are hatched to indicate cross sections, but hatching is omitted for other members to clarify the illustration.

[0032] In this embodiment, two press moldings are performed in the sequential execution of steps 1 to 5 shown in FIGS. 2 to 6. The first press is performed in steps 1 to 3 shown in FIGS. 2 to 4, and the second press is performed in steps 3 to 6 shown in FIGS. 4 to 6. In this embodiment, the first and second presses are performed using the same mold 100, but the first and second presses may be performed using different molds. Furthermore, the metal-resin composites 1 may be produced one by one, i.e., the first and second presses may be performed consecutively. Alternatively, the molding of the required number of metal plates 10 (first press) may be repeatedly performed, and then the integral molding of the metal plates 10 and the resin material 20 (second press) may be repeatedly performed. Note that, as will be described in detail later, there is a need for the resin material 20 to be placed on the metal plate 10 and for the attachment and detachment of the elastic member 124. Therefore, the latter method is preferable from the viewpoint of shortening these times.

[0033] The apparatus 50 for producing the 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 100. The drive unit 130 and the heating unit 140 may be known units that are capable of performing press molding, and are shown only in Fig. 2 as a conceptual diagram without showing details, and are not shown in Fig. 3 and subsequent figures.

[0034] The mold 100 is used to press-form a metal plate 10 and a resin material 20 to produce a 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 is movable in the vertical direction by a drive unit 130, i.e., configured to be able to move toward and away from the lower mold 120. However, the manner in which the drive unit 130 drives the mold 100 is not particularly limited, and the drive unit 130 may move at least one of the upper mold 110 and the lower mold 120 in the vertical direction.

[0035] Upper mold 110 has a first molding upper surface 111 that molds bottom wall portion 2 (see FIG. 1), a second molding upper surface 112 that molds side wall portion 3 (see FIG. 1), and a third molding upper surface 113 that molds flange portion 4 (see FIG. 1). In this embodiment, first molding upper surface 111 and third molding upper surface 113 are configured as horizontal surfaces, and second molding upper surface 112 connects first molding upper surface 111 and third molding upper surface 113 and is configured to be inclined from the vertical direction.

[0036] 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.

[0037] Lower mold 120 has a first molding lower surface 121 that molds bottom wall portion 2 (see FIG. 1), a second molding lower surface 122 that molds side wall portion 3 (see FIG. 1), and a third molding lower surface 123 that molds flange portion 4 (see FIG. 1). In this embodiment, first molding lower surface 121 and third molding lower surface 123 are configured as horizontal surfaces, and second molding lower surface 122 connects first molding lower surface 121 and third molding lower surface 123 and is configured to be inclined from the vertical direction. First molding lower surface 121 is disposed opposite first molding upper surface 111, second molding lower surface 122 is disposed opposite second molding upper surface 112, and third molding lower surface 123 is disposed opposite third molding upper surface 113.

[0038] In this embodiment, a holding groove 122b is provided in the second molded lower surface 122. The holding groove 122b is a recess for holding an elastic member 124, which will be described later, and has a depth in a direction perpendicular to the second molded lower surface 122. However, the holding groove 122b is not an essential component and can be omitted as necessary.

[0039] In the first step shown in Fig. 2, the upper mold 110 and the lower mold 120 are heated by the heating unit 140 to prepare them for warm pressing. Furthermore, the flat metal sheet 10 before forming is placed on the lower mold 120. Here, forming of the metal sheet 10 (first pressing) may be performed either warm or cold. However, when the first pressing and the second pressing are performed consecutively as described above, from the viewpoint of production efficiency, it is preferable to also perform forming of the metal sheet 10 (first pressing) by warm pressing.

[0040] 3, the upper die 110 is lowered, and the metal sheet 10 is sandwiched between the upper die 110 and the lower die 120 and press-formed into a generally hat shape. When the upper die 110 and the lower die 120 are closed, the distance d1 between the first upper molding surface 111 and the first lower molding surface 121 is greater than the thickness t of the metal sheet 10 (d1>t), and the distance d3 between the third upper molding surface 113 and the third lower molding surface 123 is approximately equal to the thickness t of the metal sheet 10 (d3=t). Furthermore, the distance d21 between the second upper molding surface 112 and the second lower molding surface 122 below the step 112a is greater than the thickness t of the metal sheet 10 (d21>t), and the distance d22 between the second upper molding surface 112 and the second lower molding surface 122 above the step 112a is approximately equal to or slightly greater than the thickness t of the metal sheet 10 (d22=t or d22>t). In particular, by setting the distance d22 equal to the thickness t of the metal sheet 10, the filling pressure of the resin material 20 in the subsequent process can be increased. Note that in this process, the resin material 20 (see FIGS. 4 to 6) has not yet been filled, and only the metal sheet 10 is sandwiched between the upper mold 110 and the lower mold 120. When the upper mold 110 and the lower mold 120 are closed, 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 (more specifically, the metal plate 10).

[0041] In the third step shown in FIG. 4, the upper mold 110 is raised. At this time, the metal plate 10 is formed into a roughly hat-shaped shape that is close to the final shape (see FIG. 1). After the upper mold 110 is raised, an elastic member 124 is attached to the holding groove 122b of the lower mold 120 for the second pressing. The elastic member 124 has elasticity and is made of, for example, silicone rubber. In this embodiment, the elastic member 124 has a rectangular parallelepiped shape extending along the holding groove 122b and is rectangular in cross section in FIG. 4. The elastic member 124 is arranged to seal the resin material 20 within the cavity C. When attached to the holding groove 122b, the elastic member 124 protrudes from the second molding lower surface 122. After the elastic member 124 is attached, a sheet-like resin material 20 (also called a 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 pressure by a molding method known as the SMC (Sheet Molding Compound) method (see the fourth step described below). In this embodiment, a fiber reinforced plastic (FRP) made by impregnating a resin with glass fiber or carbon fiber 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., it has not yet been cured. The resin material 20 does not need to be in a sheet shape and can have any shape.

[0042] In the fourth step shown in FIG. 5, the upper mold 110 is lowered, and the metal sheet 10 and the resin material 20 are sandwiched between the upper mold 110 and the lower mold 120 and press-molded into a complete hat shape. In this embodiment, the elastic member 124 is attached at a position higher than the step 112a when the upper mold 110 and the lower mold 120 are closed (see FIG. 5). The elastic member 124 presses the metal sheet 10 against the upper mold 110 (particularly the second molding upper surface 112 above the step 112a), thereby sealing the resin material 20 in the cavity C. In this manner, the resin material 20 cut to the required dimensions by the SMC method is poured into the mold 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 metal sheet 10 being sandwiched between the upper mold 110 and the lower mold 120 (specifically, the metal sheet 10). The resin material 20 is heated in the cavity C and hardens without leaking out of the cavity C. At this time, the end surface 20a of the resin material 20 abuts against the step 112a.

[0043] In the fifth step shown in FIG. 6, the upper mold 110 is raised. The metal plate 10 is formed into a final shape (hat-shaped in this embodiment), and a resin material 20 is fixed to the upper surface (concave surface of the hat-shape) of the metal plate 10, thereby forming a metal-resin composite 1. The elastic member 124 can be restored to its original shape due to its elasticity and is reusable. Preferably, the elastic member 124 has heat resistance sufficient to withstand the heat from the heating unit 140 (see FIG. 2).

[0044] FIG. 7 is an enlarged cross-sectional view of a portion VII circled by a broken line in FIG.

[0045] In this embodiment, the holding groove 122b is provided at a position 6 mm downward from the third molded lower surface 123 (D1 = 6 mm). The corner that forms the boundary between the second molded lower surface 122 and the third molded lower surface 123 is formed by a curved surface with a radius of 5 mm. The holding groove 122b is provided in the second molded upper surface 112, not in the corner. The holding groove 122b has a depth D2 of 4 mm and a width D3 of 5 mm.

[0046] In this embodiment, the elastic member 124 is a square with sides of 5 mm in the cross section of Fig. 7. Therefore, the elastic member 124 protrudes 1 mm from the holding groove 122b (T = 1 mm). That is, the thickness (T + D2) of the elastic member 124 is thicker than the depth D2 of the holding groove 122b by the thickness T.

[0047] As will be described later, the shapes of the retaining groove 122b and the elastic member 124 are not limited to those described above, and may vary.

[0048] According to this embodiment, the metal plate 10 is pressed against the upper mold 110 by the elastic member 124, so that the resin material 20 is sealed in the cavity C. This makes it possible to prevent the resin material 20 from leaking out of the cavity C, and to prevent the resin material 20 from leaking to unintended locations (such as the flange portion 4). By preventing the resin material 20 from leaking out, the filling pressure of the resin material 20 in the cavity C increases, and stable molding of the resin material 20 can be achieved. Therefore, a metal-resin composite 1 with stable quality can be manufactured.

[0049] In this embodiment, the cross-sectional shape of the metal-resin composite body 1 is formed into a hat shape. The hat-shaped metal-resin composite body 1 is highly versatile and can be used for a variety of purposes.

[0050] Furthermore, in order for the resin material 20 to leak out of the cavity C, it is necessary for the resin material 20 to flow over the step 112a of the upper mold 110, which prevents leakage of the resin material 20. Therefore, the filling pressure of the resin material 20 in the cavity C can be increased, and the quality can be improved.

[0051] Furthermore, in this embodiment, the elastic member 124 can be held by the holding groove 122b, so that the elastic member 124 can be easily positioned and movement of the elastic member 124 during molding can be restricted. Furthermore, because the elastic member 124 protrudes from the second molding lower surface 122, it is sandwiched between the upper mold 110 (more specifically, the metal plate 10) and the lower mold 120 and receives a compressive force. This improves the effectiveness of the sealing function of the elastic member 124. Note that, although the above example shows the elastic member 124 made of silicone rubber, it may alternatively be made of an elastic member such as a corrugated metal plate.

[0052] FIG. 8 is a cross-sectional view showing a first modified example of FIG.

[0053] In the cross section shown in the figure, the elastic member 124 of the first modified example has a chamfered end 124a that protrudes from the holding groove 122b. The chamfer is, for example, a C-chamfer with a chamfer angle of 45°.

[0054] FIG. 9 is a cross-sectional view showing a second modification of FIG.

[0055] In the second modification, the elastic member 124 has a rounded end 124a protruding from the holding groove 122b in the cross section shown in the figure. The rounded shape is, for example, a semicircular shape in the cross section shown in the figure.

[0056] According to the first and second modified examples, it is possible to prevent the end 124a protruding from the holding groove 122b from deforming so as to widen along the second molding lower surface 122 and becoming unintentionally pinched between the metal plate 10 and the lower mold 120. This makes it possible to prevent damage to the elastic member 124 or mold galling (abnormal wear). In particular, it is possible to prevent mold galling (abnormal wear) caused by an excessive increase in the compressive force between the upper mold 110 and the metal plate 10.

[0057] FIG. 10 is a cross-sectional view showing a third modified example of FIG.

[0058] In the third modified example, in the cross section shown in the figure, not only the end 124a protruding from the holding groove 122b but also the end 124b inserted into the holding groove 122b is chamfered. The chamfering is, for example, a C-chamfer with a chamfer angle of 45°.

[0059] FIG. 11 is a cross-sectional view showing a fourth modification of FIG.

[0060] In the fourth modified example, the elastic member 124 has a rounded shape not only at the end 124a protruding from the holding groove 122b but also at the end 124b inserted into the holding groove 122b. The rounded shape is, for example, a semicircular shape in the cross section shown in the figure. That is, the elastic member 124 of this modified example has a circular shape in the cross section shown in the figure.

[0061] According to the third and fourth modified examples, it is possible to ensure a deformation margin (deformation allowance) for the elastic member 124 within the holding groove 122b. If the elastic member 124 does not have a deformation margin, extremely high pressure may be applied to the elastic member 124, which may cause mold seizing. In particular, it is possible to suppress mold seizing (abnormal wear) caused by an excessive increase in the compressive force between the upper mold 110 and the metal plate 10.

[0062] FIG. 12 is a cross-sectional view showing a fifth modification of FIG.

[0063] In the fifth modified example, in the cross section shown in the figure, the elastic member 124 is chamfered not only at the end 124a protruding from the holding groove 122b but also at the end 124b inserted into the holding groove 122b. The chamfering is, for example, a C-chamfer with a chamfer angle of 45°. Furthermore, the elastic member 124 of the fifth modified example has a cavity 124c in the center thereof. In the cross section shown in the figure, the cavity 124c is circular.

[0064] According to the fifth modification, the flexibility of the elastic member 124 is improved, and it is possible to prevent die seizing caused by extremely high pressure being applied to the elastic member 124. In particular, it is possible to prevent die seizing (abnormal wear) caused by an excessive increase in the compressive force between the upper die 110 and the metal plate 10.

[0065] FIG. 13 is a cross-sectional view showing a sixth modification of FIG.

[0066] In the sixth modified example, the holding groove 122b has a shape in which the bottom 122b2 is wider than the opening 122b1 in the cross section shown in the figure. Specifically, the inner surface 122b3 connecting the opening 122b1 and the bottom 122b2 is tapered so as to narrow from the bottom 122b2 toward the opening 122b1. The elastic member 124 also has an end 124a shaped similarly to the fifth modified example and an end 124b shaped complementary to the holding groove 122b.

[0067] FIG. 14 is a cross-sectional view showing a seventh modification of FIG.

[0068] In the seventh modified example, the holding groove 122b has a shape in which the bottom 122b2 is wider than the opening 122b1 in the cross section shown in the figure, similar to Fig. 13. More specifically, the inner surface 122b3 connecting the opening 122b1 and the bottom 122b2 has a stepped shape that narrows from the bottom 122b2 toward the opening 122b1. The elastic member 124 also has an end 124a shaped similarly to the fifth modified example and an end 124b shaped complementary to the holding groove 122b.

[0069] According to the sixth and seventh modifications, the elastic member 124 (particularly the end 124b) is caught in the holding groove 122b, thereby preventing the elastic member 124 from coming off the holding groove 122b. In this embodiment, the end 124b of the elastic member 124 has a shape complementary to that of the holding groove 122b, but this is not limitative. During press molding, the elastic member 124 is subjected to pressure and deforms to fit the shape of the holding groove 122b, so the effect of preventing the elastic member 124 from coming off can be achieved regardless of the shape of the elastic member 124.

[0070] (Second embodiment) An apparatus 50 and method for manufacturing a metal resin composite 1 in a second embodiment will be described with reference to Fig. 15. In this embodiment, the shape of the metal resin composite 1 is different from that in the first embodiment. Other than this, the configuration is the same as that of the first embodiment shown in Figs. 1 to 6. Therefore, the description of the parts shown in the first embodiment may be omitted.

[0071] In this embodiment, the metal-resin composite 1 has a protrusion 2a on the bottom wall portion 2. The protrusion 2a is made of a resin material 20 and extends vertically upward in an elongated shape. In addition, a recess 111a having a shape complementary to the protrusion 2a is formed in the first molded upper surface 111. The recess 111a opens downward in the first molded upper surface 111.

[0072] When molding the resin material 20 into a long and thin shape like the protrusion 2a, a sufficient filling pressure is required, but here, the filling pressure of the resin material 20 is increased by the elastic member 124, so that even a long and thin shape like the protrusion 2a can be stably molded.

[0073] While specific embodiments and modifications of the present invention have been described above, the present invention is not limited to the above-described embodiments and can be implemented with various modifications within the scope of the present invention. For example, an appropriate combination of the contents of the individual embodiments and modifications may be used as an embodiment of the present invention.

[0074] 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. The resin material 20 is then cooled and hardened on the metal plate 10 within the mold 100, thereby producing the metal resin composite 1.

[0075] Furthermore, 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 member 10 and the resin material 20 can be firmly molded into one piece.

[0076] 16, the metal sheet 10 may be press-formed into a perfect hat shape in the second step (first press). In this case, an upper die 110A having a perfect hat-shaped forming surface is used so that the metal sheet 10 is press-formed into a perfect hat shape. Alternatively, the same upper die may be used for the first and second presses. In the example of FIG. 16, the elastic member 124 is not attached to the retaining groove 122b. This is because the resin material 20 is not placed in the first press, and therefore there is no need to attach the elastic member 124 to prevent leakage of the resin material 20. Note that different lower dies may be used for the first and second presses, and the lower die used in the first press may not have the retaining groove 122b. [Explanation of symbols]

[0077] 1 Metal resin composite 2 Bottom wall 3 Side wall 4 Flange 10 Metal plates (metal parts) 20 Resin material 20a end face 50 equipment 100 molds 110,110A upper type 111 1st molding top surface 111a recess 112 Second molding top surface 112a Steps 113 Third molding top surface 120 Lower mold 121 First molding bottom surface 122 Second molding bottom surface 122b Retaining groove 122b1 opening 122b2 bottom 122b3 Inside surface 123 Third molding bottom surface 124 Elastic member 124a,124b End 130 Drive unit 140 Heating section C cavity

Claims

1. A method for producing a metal-resin composite by press-molding a metal member and a resin material, comprising: a lower mold, the metal member, the resin material, and an upper mold are arranged in this order; the metal member and the resin material are sandwiched between the upper mold and the lower mold; the metal member is pressed against the upper mold via an elastic member attached to the molding surface of the lower mold by the sandwiching, thereby sealing a cavity formed by the upper mold and the lower mold; The metal member and the resin material are integrated by the press molding while the resin material is sealed in the cavity. A method comprising:

2. In a cross section perpendicular to the longitudinal direction, the metal-resin composite has a bottom wall portion extending horizontally, side wall portions rising from both ends of the bottom wall portion, and flange portions extending horizontally outward from the side wall portions, the upper mold has, in the cross section, a first molding upper surface that molds the bottom wall portion, a second molding upper surface that molds the side wall portion, and a third molding upper surface that molds the flange portion; The method according to claim 1, wherein the lower mold has, in the cross section, a first molding lower surface that molds the bottom wall portion, a second molding lower surface that molds the side wall portion, and a third molding lower surface that molds the flange portion.

3. The method of claim 2 , wherein the second upper mold surface is stepped.

4. The second molded lower surface is provided with a holding groove for holding the elastic member, The method of claim 3 , wherein the thickness of the resilient member is greater than the depth of the retention groove.

5. The method according to claim 4 , wherein the retaining groove has a shape in the cross section where the bottom is wider than the opening.

6. The method according to claim 4 or claim 5, wherein the holding groove is positioned at the same height as the step or at a higher height than the step in the cross section when the upper mold and the lower mold are closed.

7. The method according to any one of claims 4 to 6, wherein the elastic member has a chamfered or rounded shape at the end protruding from the retaining groove in the cross section.

8. The method according to any one of claims 4 to 7, wherein the elastic member has a chamfered or rounded shape at the cross section at an end that is inserted into the retaining groove.

9. The method described in claim 1, further comprising press-molding only the metal member into a hat shape before integrating the metal member and the resin material by press-molding.

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