JP2009255486A - Method for manufacturing of molded product with metal sheet, and mold for molded product with metal sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing of a molded product with a metal sheet capable of easily joining the metal sheet with a molding mold, and a mold for the molded product with the metal sheet. <P>SOLUTION: The method for manufacturing of the molded product 10 with the metal sheet made by integrating the metal sheet 30 with a resin molded part 40 includes a step of setting the metal sheet 30 on the first molding mold 51 before moving the second molding mold 52 to close the molds, and further includes steps of forming a tilting surface 34 on the contact surface of the metal sheet 30 with the second molding mold 52 or the approximately whole of the surface along the moving direction of the second molding mold 52 in a thickness direction of the sheet and bringing a surface 59 of the second molding mold 52 in contact with the metal sheet 30 and having an inclination aligned with the tilting surface 34 formed on the metal sheet 30 into contact with the tilting surface 34 formed on the metal sheet 30 to close the molds. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a molded product with a metal plate in which a metal plate and a resin molded part are integrated, and a mold for the molded product with a metal plate.

Conventionally, a molded product with a metal plate in which a metal plate and a resin molded portion are integrated is known (for example, Patent Document 1). In this molded product with a metal plate, the metal plate is set in the first mold constituting the mold, the second mold is moved to close the mold, and then the mold cavity is filled with resin. It is manufactured by doing.
JP 2008-6722 A

  By the way, when manufacturing a molded product with a metal plate as described above, depending on the structure of the molded product, the edge of the metal plate and the second molding die may be in direct contact with each other in the mold closed state. In such a case, when the second molding die is moved and closed, there is a concern that the second molding die contacts the edge of the metal plate, the contact portion is scraped, and metal powder is generated.

  For this reason, after punching the metal plate, a process for accurately matching the contour of the metal plate with the shape of the second mold is performed. However, since such high-precision processing takes a lot of work, a device for easily matching the metal plate and the forming die has been desired.

  This invention was completed based on the above situations, Comprising: The manufacturing method of the molded product with a metal plate which can match | combine a metal plate and a shaping | molding die easily, and shaping | molding for a molded product with a metal plate The purpose is to provide a mold.

  The method for producing a molded product with a metal plate according to the present invention is a method for producing a molded product with a metal plate in which a metal plate and a resin molded part are integrated, and after setting the metal plate in a first mold, In what closes the mold by moving the second mold, of the contact surface of the metal plate with the second mold, the surface along the moving direction of the second mold is substantially over the entire plate thickness direction. A step of forming an inclined surface to be inclined is performed, and a contact surface with the metal plate forming an inclination that matches the inclined surface formed on the metal plate of the second mold is formed on the metal plate. The mold is brought into a closed state by contacting with an inclined surface.

  According to such a configuration, the second mold and the metal plate are shaved from each other when the second mold is moved and closed without performing high-precision processing on the metal plate as in the prior art. Since they are in contact with each other without contact, the metal plate and the mold can be easily combined.

  The step of forming the inclined surface may be performed during the punching step of the metal plate. Thereby, compared with the case where the punching process of a metal plate and the formation process of an inclined surface are performed in a separate process, the molded product with a metal plate can be manufactured efficiently.

  A molding die for a molded product with a metal plate according to the present invention is a molding die for molding a molded product with a metal plate in which a metal plate and a resin molded part are integrated, and is capable of setting the metal plate. A first mold and a second mold that moves relative to the first mold; the second mold is a surface of the metal plate along the moving direction of the second mold; It has a feature that it has an abutting surface that makes an inclination that matches the inclined surface attached to the surface.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the molded product with a metal plate which can match | combine a metal plate and a shaping | molding die easily, and the shaping | molding die for molded products with a metal plate can be provided.

Hereinafter, embodiments of the present invention will be described with reference to FIGS.
A molded product 10 with a metal plate (hereinafter simply referred to as a molded product 10) in the present embodiment is installed inside a transmission of an automobile. This molded product 10 is obtained by integrally molding a primary molded product 20 having a bus bar 21 incorporated therein and a metal plate 30 by a secondary molded part 40 (corresponding to a resin molded part of the present invention). Hereinafter, in each component member, the upper side in FIG. 1 will be described as the upper side, and the lower side will be described as the lower side.

  The primary molded product 20 is obtained by integrally molding a plurality of bus bars 21 and a synthetic resin primary molded portion 22 by insert molding. The plurality of bus bars 21 are embedded in the primary molding portion 22 in a posture in which one end protrudes from the side surface of the primary molding portion 22. The tip of the portion of the bus bar 21 that protrudes from the side surface of the primary molding portion 22 protrudes from the side surface of the secondary molding portion 40. A protruding portion from the secondary molding portion 40 of the bus bar 21 is a terminal portion 23 that can be connected to a mating terminal (not shown), and each terminal portion 23 has a rivet hole 24 that enables riveting with the mating terminal. Is formed.

  One metal plate 30 is arranged on the upper surface of the primary molded product 20 with the plate surface being in a direction substantially parallel to the terminal portion 23 of the bus bar 21. Through holes 31 that penetrate the metal plate 30 in the plate thickness direction are provided at a plurality of portions of the metal plate 30 that are in contact with the secondary forming portion 40. The substantially half on the upper side of each through hole 31 has a mortar shape that gradually decreases in diameter toward the lower side, and the approximately half on the lower mold side has a substantially circular cross section with a substantially constant diameter. Each through-hole 31 is filled with a resin material at the time of forming the secondary molded portion 40, and the filled resin material functions as an anchor, and the metal plate 30 and the secondary molded portion 40 are firmly integrated.

  The upper surface of the metal plate 30 is an upper exposed surface 32 that is exposed from the secondary forming portion 40 over substantially the entire surface. And the surrounding surface of the metal plate 30 is comprised from the coating | coated surface 33 covered with the secondary shaping | molding part 40, and the side part exposed surface 34 which is not covered with the secondary shaping | molding part 40 but is exposed outside. The side exposed surface 34 is inclined so as to gradually protrude outward (outside in the plate surface direction) from the upper exposed surface 32 toward the lower surface, in other words, a portion facing the upper mold 52 from the upper exposed surface 32 toward the lower surface. The slope is increasing. The side exposed surface 34 is a surface along the moving direction of the upper mold 52 among the contact surfaces with the upper mold 52 (that is, the upper exposed surface 32 and the side exposed surface 34), and corresponds to the inclined surface of the present invention. To do. The side exposed surface 34 is inclined over substantially the entire plate thickness direction of the metal plate 30, and the inclination angle is about 45 degrees with respect to the plate surface of the metal plate 30. In addition, although the inclination angle of the side part exposed surface 34 may be any angle, it is preferably set between 45 degrees and 60 degrees in consideration of a plate thickness dimension and the like.

  A press punching die (not shown) for punching the metal plate 30 is provided with an inclined portion capable of punching the metal plate material by inclining the side exposed surface 34 of the metal plate 30, and the metal plate material is press punched. When the metal plate 30 is sheared after being set in the mold, the side exposed surface 34 is inclined and the metal plate 30 is formed.

  A mold 50 for molding the molded product 10 includes a lower mold 51 (corresponding to the first mold of the present invention) on which the metal plate 30 can be set, and an upper mold that moves relative to the lower mold 51. 52 (corresponding to the second mold of the present invention). The lower mold 51 is provided with a positioning projection (not shown) for setting the primary molded product 20 and the metal plate 30.

  A slide mold 53 is attached to the upper surface of the lower mold 51 so as to be slidable in a substantially horizontal direction (a direction substantially orthogonal to the moving direction of the upper mold 52). The slide mold 53 is provided with a support hole 53A into which the terminal portion 23 of the primary molded product 20 is inserted.

  The upper mold 52 is movable in a vertical direction (approaching / separating direction with respect to the lower mold 51) with a predetermined stroke. Of the lower end of the upper die 52 (the portion facing the lower die 51), the surface in the substantially horizontal direction is the mold closing surface 54 pressed against the upper surface of the slide die 53 or the upper surface of the lower die 51, and the upper exposure of the metal plate 30. It is comprised from the upper contact surface 55 pressed against the surface 32, and the upper shaping | molding surface 57 which comprises the cavity 56 of the secondary shaping | molding part 40 (refer FIG. 3 and FIG. 4). In addition, the surface in the direction along the moving direction of the upper mold 52 among the lower ends of the upper mold 52 is the side molding surface 58 that constitutes the cavity 56 of the secondary molding section 40 and the side exposed surface 34 of the metal plate 30. It is comprised from the side contact surface 59 (it corresponds to the contact surface of this invention) pressed on. The side contact surface 59 is inclined to align with the side exposed surface 34 of the metal plate 30, and comes into surface contact with the side exposed surface 34 in the mold closed state.

Next, a method for manufacturing the molded product 10 will be described.
First, the metal plate material is subjected to press punching to form the metal plate 30 having a shape in which the side exposed surface 34 is inclined (inclined surface forming step and punching step). Next, the metal plate 30 and the primary molded product 20 are set on the lower mold 51. The metal plate 30 is placed and positioned on the upper surface side of the primary molded product 20 with the upper exposed surface 32 facing upward and the plate surface being substantially horizontal.

  Next, the slide mold 53 is slid and set between the metal plate 30 and the lower mold 51. The slide mold 53 is set at a predetermined position in a state where the terminal portion 23 of the primary molded product 20 is inserted into the support hole 53A. Note that the end surface of the slide mold 53 (the end surface on the side where the support hole 53 </ b> A is formed and the surface constituting the cavity 56) rises substantially perpendicularly to the upper surface of the lower mold 51.

  Thereafter, the upper mold 52 is moved downward to make the mold closed. The side abutment surface 59 of the upper mold 52 is gradually approached as the upper mold 52 is lowered while facing the side exposed surface 34 of the metal plate 30 in the vertical direction. The upper contact surface 55 contacts the upper exposed surface 32 of the metal plate 30 at the same time as the mold closing surface 54 of the upper mold 52 contacts the upper surface of the lower mold 51 and the upper surface of the slide mold 53. The part abutment surfaces 59 abut against the side exposed surfaces 34 of the metal plate 30, respectively, and the mold 50 is in the mold closed state.

  Next, when the mold is opened after the molten resin is injected from the gate (not shown) into the cavity 56 and the resin is solidified, the primary molded product 20 and the metal plate 30 are integrated by the secondary molded portion 40. The formed molded product 10 is taken out, and the production of the molded product 10 is completed.

According to the present embodiment configured as described above, the following effects can be obtained.
Of the contact surface with the upper mold 52 of the metal plate 30, the surface along the moving direction of the upper mold 52 (side exposed surface 34) is inclined over substantially the entire plate thickness direction, and the inclination of the side exposed surface 34 is increased. The side contact surface 59 of the upper mold 52 having the aligned inclination is brought into contact with each other so that the mold is closed. Therefore, even if the metal plate 30 is not processed with high accuracy as in the prior art, the upper die 52 and the metal plate 30 are in contact with each other without being scraped when the die is closed. The mold 50 can be easily matched.

  Further, since the inclination of the side exposed surface 34 of the metal plate 30 is formed at the time of punching (the inclined surface forming process and the punching process are performed at the same time), compared with the case where these processes are performed in separate processes. Thus, the molded product 10 can be efficiently manufactured.

  The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.

(1) In the above embodiment, the slide mold 53 is set after the primary molded product 20 and the metal plate 30 are set on the lower mold 51. However, before the metal plate 30 is set, the slide mold 53 is set. Also good.
(2) In the above-described embodiment, the present invention is applied to the molded product 10 in which the primary molded product 20 and the metal plate 30 are integrated by the secondary molded portion 40. However, the present invention is not limited to this. It can be applied to a molded product integrated with a material.

Side sectional view of the molded product according to this embodiment Side sectional view showing the state where the primary molded product and metal plate are set in the lower mold Side sectional view showing the state before mold closing Side sectional view showing the state after mold closing Side sectional view showing the state where the secondary molded part is molded

Explanation of symbols

10 ... Molded product (molded product with metal plate)
30 ... Metal plate 34 ... Side exposed surface (inclined surface of metal plate)
40 ... Secondary molded part (resin molded part)
50: Mold 51: Lower mold (first mold)
52 ... Upper mold (second mold)
59 ... Side contact surface (contact surface)

Claims (3)

A method of manufacturing a molded product with a metal plate in which a metal plate and a resin molded part are integrated, wherein after the metal plate is set in a first mold, the second mold is moved to a mold closed state In
Performing a step of forming an inclined surface that is inclined over substantially the entire plate thickness direction of the surface along the moving direction of the second forming die among the contact surfaces of the metal plate with the second forming die;
The abutment surface of the second molding die with the inclined surface formed on the metal plate is brought into contact with the inclined surface formed on the metal plate to be in the mold closed state. A method for producing a molded article with a metal plate. The method of manufacturing a molded product with a metal plate, wherein the inclined surface forming step is performed during the punching step of the metal plate. A molding die for molding a molded product with a metal plate in which a metal plate and a resin molded part are integrated,
A first mold that can set the metal plate, and a second mold that moves relative to the first mold;
The second molding die has a metal plate-equipped abutment surface having an abutting surface that matches an inclined surface attached to a surface of the metal plate along the moving direction of the second molding die. Mold for use.

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