Metal Composite Production via Preform Molding
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Solution Overview
Problem
Conventional methods for producing metal composites, such as those used in electronic equipment chassis, face inefficiencies in composite production, including low production efficiency, difficulty in achieving strong bonding, and limitations in design flexibility and lightweighting, due to separate processing steps for metal and fiber-reinforced resin materials.
Innovation Solution
A method involving the use of a preform with a thermosetting resin sheet substrate and metal material, where the preform is heated and pressed to form a metal composite with a cured resin layer, allowing for integration of metal materials and other structural materials through a cured resin layer, enabling complex shape processing and high bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate processing steps are used for metal material molding and fiber-reinforced resin molding, then each material can be processed with appropriate methods, but production efficiency is low and production cost is high
Solution Approach 1:
The patent combines the metal material molding step and the fiber-reinforced resin molding step into a single integrated process. The metal material is molded first, then the fiber-reinforced resin is molded while the metal material is still in the mold, allowing both materials to be processed together in one operation rather than separately, thereby improving production efficiency without sacrificing the appropriateness of processing methods for each material
2Shape
If thermosetting resin is introduced after metal material is molded into complex shape, then metal shape can be achieved, but bonding strength cannot be guaranteed and flaking occurs
Solution Approach 1:
The patent applies preliminary action by introducing the thermosetting resin before the metal material is fully molded into its final complex shape. The resin is placed in the mold first, then the metal material is molded over it. This preliminary introduction of the resin allows it to be properly positioned and bonded to the metal material during the molding process, preventing flaking and ensuring adequate bonding strength while still achieving the required complex shape
3Strength
If resin binder layer is added to integrate metal material and fiber-reinforced resin, then bonding strength is improved, but design freedom is reduced and weight increases
Solution Approach 1:
The patent merges the bonding function with the structural resin component by having the thermosetting resin serve both as the bonding agent between metal materials and as the structural fiber-reinforced resin component. This eliminates the need for a separate resin binder layer, maintaining bonding strength while preserving design freedom and reducing weight by removing redundant material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances production efficiency, achieves strong bonding between metal and resin layers, and allows for complex shape formation, addressing the limitations of conventional methods by improving amenability to thin-walling, design freedom, and reducing production costs.
Implementation Method 1
heating and pressurizing a preform including a sheet substrate containing a thermosetting resin and a metal material disposed in contact with the sheet substrate or laminated therewith to form the metal composite comprising the metal material and a cured resin layer formed by curing the thermosetting resin
Implementation Method 2
a step 1 for placing the preform in a mold and heating the metal material to a temperature in excess of 180° C.
Implementation Method 3
a step 2 for applying a pressure to the preform being heated in the step 1 to form a composite material
Data Source
AI summary
A method is provided for producing a metal composite. The composite includes a metal material and a resin curing layer provided along the metal material, and is obtained by using heat and pressure to mold a preform. The preform includes a sheet-shaped base material containing a thermosetting resin, and a metal material arranged or layered so as to contact the sheet-shaped base material. The method for producing a metal composite includes heating the sheet-shaped base material and semi-curing the thermosetting resin while the metal material in the preform arranged inside a mold is heated to a temperature exceeding 180° C., and molding the preform into a composite using pressure, wherein the thermosetting resin is at least one type selected from the group consisting of epoxy resins, phenol resins, benzoxazine resins, and unsaturated polyester resins.