JP2012183914A - Composite and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently obtain a composite having a good appearance quality since the generation of deform is avoided.SOLUTION: The composite 10 is configured by jointing a resin material 14 to a workpiece 12 comprised of metal. The resin material 14 is jointed to the workpiece 12 in a spot form at a plurality of positions. That is, a plurality of point-jointing portions 24 are formed at the resin material 14. As the preferable example of the resin material 14, a thermoplastic resin such as a polyamide resin (nylon) is cited. This kind of composite is preferably adopted, for example, as a vehicular part such as a door panel.

Description

  The present invention relates to a composite body made of a metal workpiece and a resin material and a manufacturing method thereof, and more specifically, for example, a composite body in which a resin material that reinforces a steel plate such as a door panel for a vehicle is joined and It relates to the manufacturing method.

  In recent years, increasing interest in environmental protection has been attempted to improve the fuel efficiency of automobiles. This is because the fuel consumption is reduced by improving the fuel consumption, so that resources are saved and the amount of exhaust gas discharged from the internal combustion engine is reduced.

  From this viewpoint, it has been conventionally performed to reduce the weight of vehicle components. This is because the load on the internal combustion engine is reduced as the vehicle weight is reduced, so that fuel efficiency can be improved. One example of a specific attempt is to reduce the thickness of a metal panel such as a door panel.

  However, if the thickness is reduced, the rigidity of the metal panel is lowered. Therefore, in order to ensure rigidity, a resin material is joined to the metal panel and reinforced. For example, in Patent Document 1, a reinforcing material based on a thermosetting resin is applied to a metal panel (steel plate) serving as a vehicle component, and then the reinforcing material is cured by heating to reinforce the reinforcing material. It has been proposed to form a layer.

JP 2007-296875 A

  In the technique described in Patent Literature 1, the thermosetting resin is applied and then heated to form the reinforcing layer. That is, in this case, the entire applied thermosetting resin is heated and cured, and in this state, is bonded to the metal panel.

  In this process, the thermosetting resin and the metal panel expand due to heating, and then shrink due to cooling (cooling), but due to the mismatch in the thermal expansion coefficient between the thermosetting resin and the metal panel, Inside the metal panel is pulled by the thermosetting resin. For this reason, the malfunction that a local deformation | transformation tends to arise in a metal panel has become obvious.

  Further, since the entire thermosetting resin is heated together with the metal panel, it takes a long time from the start of heating to the end of cooling. Therefore, the cycle time until obtaining the reinforcing layer becomes longer.

  Furthermore, the amount of elastic deformation when an external force is applied is different between the metal panel and the reinforcing layer (resin material). Due to this, there is a concern that the reinforcing layer may be peeled off from the metal panel when the metal panel is deformed as an external force acts.

  The present invention has been made in order to solve the above-described problems. Since the occurrence of deformation is avoided, the appearance quality is good, and it can be obtained in a short time, and further, a reinforcing layer is formed. It aims at providing the composite_body | complex which a resin material does not peel easily from a workpiece | work, and its manufacturing method.

In order to achieve the above object, the present invention is a composite constituted by joining a long resin material to a workpiece made of metal,
A plurality of points of the resin material are depressed toward the workpiece, and point bonding portions are formed in a spot shape with respect to the workpiece.

  According to such a structure, since a point joining site is formed, the joining area between the metal workpiece and the resin material that reinforces it is reduced. For this reason, since the range in which the tensile force generated due to the mismatch between the thermal expansion coefficients of the workpiece and the resin material acts is narrowed, the tensile force can be reduced. Therefore, in the composite according to the present invention, the occurrence of deformation is avoided, and thus the appearance quality is good.

  In addition, since the portions other than the point joining portions are not heated, they are not softened and remain in a hard state. The hard part suppresses the point joining part from expanding. This is because a hard part is difficult to deform. This also reduces the difference in thermal expansion between the workpiece and the resin material, which contributes to avoiding the occurrence of deformation.

  In addition, in such a configuration, even if an external force is applied, a portion other than the point joining portion in the resin material is not restrained, so that the resin material easily deforms following the external force. Therefore, the concern that the resin material peels from the workpiece is eliminated.

  Furthermore, in this case, the resin material may be heated in a dot shape, and there is no need to heat a portion other than the portion to be joined. Accordingly, until the joining of the resin material is completed, in other words, the cycle time until the composite is obtained is shortened. That is, a complex can be obtained efficiently.

  In this composite, the resin material may have a layer structure including an elastic resin layer facing the workpiece and a reinforcing resin layer positioned on the elastic resin layer. By adopting a layer structure, for example, by using a material with excellent weldability as an elastic resin layer, a strong bonding force is expressed between a metal workpiece and a resin material, and it has excellent rigidity as a reinforcing resin layer. The rigidity of the composite can be improved by using a new material.

  In this case, you may make it join parts other than the point joining part of a resin material with respect to the said workpiece | work. In particular, when the resin material has a layer structure including an elastic resin layer and a reinforcing resin layer, the elastic resin layer is an elastic body. Even so, the resin material is easily deformed in response to an external force. Therefore, the deformation is reduced and the concern that the resin material is peeled off from the workpiece is wiped out.

  Furthermore, a plurality of resin materials may be provided, and a resin material different from the resin material may be bridged between the point joint portions of the resin materials. Thus, the composite material which further improved rigidity is obtained by making resin material cross | intersect. Further, the positioning accuracy of another resin material is improved.

  In this case, in the other resin material, a part different from the part bridged by the point joining part of the resin material may be joined to the workpiece in a spot shape.

  Further, the present invention is a method for producing a composite by joining a long resin material to a metal workpiece, and heating a plurality of locations of the resin material in a spot shape. The method further comprises a step of forming a point joining portion which is depressed toward the workpiece and is joined to the workpiece in a spot shape.

  In the present invention, spot-like heating (point bonding) is performed on the resin material, so that the bonding speed is improved. Therefore, the cycle time of the bonding process can be extremely shortened as compared with the case where the entire resin material is heated.

  Further, as described above, the bonding area between the metal workpiece and the resin material that reinforces the metal workpiece is reduced as compared with the case where the entire resin material is bonded. For this reason, the range in which the tensile force acts is narrowed, and the tensile force is also reduced. Therefore, the occurrence of deformation in the workpiece is suppressed.

  As the resin material, one having a layer structure including an elastic resin layer and a reinforcing resin layer may be used. In this case, at least the elastic resin layer may be heated to a temperature at which it can be joined (welded) to the workpiece.

  In addition, you may make it perform the process of heating the said metal workpiece | work and the said whole resin material, and joining the said resin material to the said metal workpiece | work after a joining process. In this case, the rigidity can be further improved. When the elastic resin layer is provided, the resin material follows and expands / contracts even if there is a difference in the amount of thermal expansion by heating the whole. For this reason, deformation is unlikely to occur in the work.

  Further, a plurality of resin materials may be provided, and a step of bridging a resin material different from the resin material may be performed between the point joint portions of the resin material. Since the concave portion due to the depression is formed in the point joining portion, the other resin can be positioned by the concave portion. That is, it becomes easy to arrange another resin with high accuracy.

  In this case, a part different from the part bridged by the point joining part of the resin material in the another resin material may be joined to the workpiece in a spot shape.

  According to the present invention, since the resin material is bonded to the workpiece by point bonding or via a soft elastic resin layer, it is caused by a mismatch between the thermal expansion coefficients of the workpiece and the resin material. Thus, it is possible to avoid the occurrence of deformation in the complex. Therefore, a composite with good appearance quality can be obtained.

  In addition, since it is not necessary to heat the entire resin material, the time required to obtain the composite can be shortened until the bonding of the resin material is completed, in other words. That is, the cycle time can be shortened.

It is a fragmentary perspective view of the composite_body | complex which concerns on 1st Embodiment of this invention. It is an expanded sectional view of the junction part vicinity of the composite_body | complex which concerns on 1st Embodiment of this invention. It is an expanded sectional view of the junction part vicinity of the composite_body | complex which concerns on 2nd Embodiment of this invention. It is a fragmentary perspective view of the composite_body | complex which concerns on 3rd Embodiment of this invention.

  Hereinafter, preferred embodiments of the composite according to the present invention and the method for producing the same will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a partial perspective view of a waist portion of a composite body 10 according to the first embodiment of the present invention. The composite 10 is configured by arranging and joining a plurality of rod-shaped resin materials 14 substantially in parallel to a plate-shaped metal workpiece 12.

  The work 12 has a design surface 16 that is visually recognized by the user and a bonded surface 18 that is the back surface thereof. For ease of understanding, the bonded surface 18 is shown as a flat surface in FIG. 1, but the bonded surface 18 may be a non-flat surface to which the design surface 16 is recessed or raised. .

  A preferred example of this type of workpiece 12 is a vehicle component having a small thickness. More specifically, a metal panel such as a door panel is exemplified. This type of metal panel is generally made of carbon steel or the like typified by S45C.

  In this case, the resin material 14 is provided as a linear shape set to predetermined width direction dimensions and longitudinal direction dimensions with respect to the bonded surface 18 of the workpiece 12. As is well known, the resin material 14 is smaller in weight than a metal. Therefore, rigidity can be imparted to the workpiece 12 without incurring weight of the composite 10.

  The resin material 14 has a workpiece-side end surface 20 facing the bonded surface 18 and an exposed surface 22. The workpiece side end face 20 is joined to the joined face 18 in a spot shape. For this reason, the resin material 14 is formed with a plurality of point joint portions 24 that are depressed toward the joint surface 18. This is because, as will be described later, the resin material 14 is pressed toward the bonded surface 18 during bonding. Therefore, the thickness (the distance from the workpiece side end face 20 to the exposed surface 22) of the point joining part 24 is smaller than other parts. For this reason, the recessed part 26 is formed in the point joining site | part 24. FIG.

  The part corresponding to the point joining part 24 in the work side end face 20 is firmly joined to the joined surface 18 of the work 12. On the other hand, parts other than the part corresponding to the spot joining part 24 in the workpiece side end face 20 only abut against the joined surface 18 and are not joined. As can be appreciated from this, in the first embodiment, parts other than the point joining part 24 are not joined to the workpiece 12.

  As a material constituting the resin material 14, a thermoplastic resin is suitable. In this case, it is because the point joining part 24 can be easily formed by heating the resin material 14 in a spot shape. As preferable specific examples of the thermoplastic resin, for example, polyethylene resin, polypropylene resin, polystyrene resin, polyamide resin (nylon resin), acrylonitrile-butadiene-styrene copolymer (ABS) resin, acrylic resin, vinyl acetate resin, Examples include vinyl chloride resin, fluororesin, polyester resin, polycarbonate resin, and thermoplastic elastomer. In particular, it is preferable to use a polyamide resin (nylon resin).

  This composite 10 can be obtained as follows.

  First, the resin material 14 is disposed at a predetermined location on the surface 18 to be joined of the workpiece 12. As described above, the resin material 14 is preferably made of a thermoplastic resin.

  Next, a plurality of portions of the resin material 14 are heated in a spot shape and pressurized. That is, pressure bonding is performed to apply pressure to the welded parts. A part of the resin material 14 is melted by this pressure bonding, and further solidified by cooling to be integrated with the workpiece 12. In other words, a part of the resin material 14 is welded to the bonded surface 18 of the workpiece 12. Note that hot plate welding, laser welding, vibration welding, ultrasonic welding, and the like may be used.

  At the time of welding, the heated part is melted and softened, and the concave part 26 is formed by sinking the part.

  Heating to the resin material 14 at the time of welding may be performed from the work-side end surface 20 side of the resin material 14, that is, from the design surface 16 side, or from the exposed surface 22 side. Of course, the design surface 16 and the exposed surface 22 may be sandwiched.

  Here, the heating temperature at the time of welding may be set to a suitable condition in a range in which the material can be melted and a necessary bonding force with the workpiece 12 can be exhibited according to the material constituting the resin material 14. it can. The range of the portion where heat is applied to the resin material 14, that is, the size of the point bonding portion 24, can be adjusted by the heating time, the area of the hot plate used for pressure bonding, and the like. Moreover, the thickness of the point joining site | part 24 can be adjusted with the heating temperature at the time of spot welding, the pressure of crimping | compression-bonding, etc.

  After the above-described operation is repeated to form the point bonding part 24, the point bonding part 24 is cooled and solidified by being allowed to cool, and is welded to the surface to be bonded 18. During the above heating / cooling, the resin material 14 and the workpiece 12 undergo thermal expansion / contraction. However, since the resin material 14 is spot-bonded to the workpiece 12, the bonding between the workpiece 12 and the resin material 14 is performed. The area is small. Therefore, the range in which the tensile force generated due to the mismatch between the thermal expansion coefficients of the workpiece 12 and the resin material 14 acts is narrowed. Accordingly, the tensile force is reduced.

  Further, in the resin material 14, portions other than the point bonding portion 24 are not heated and thus are not softened and remain in a hard state. Since this hard part is hard to deform, it is suppressed that point joint part 24 expands too much. For this reason, the difference of the thermal expansion amount of the workpiece | work 12 and the resin material 14 becomes small. This also contributes to avoiding the occurrence of deformation in the composite 10.

  In addition, even if an external force is applied to the composite 10 having such a configuration, the resin material 14 is not restrained because no part other than the point joining part 24 is joined. Therefore, the resin material 14 easily deforms following the external force. Thereby, the concern that the resin material 14 peels from the workpiece 12 is wiped out.

  Furthermore, it is only necessary to heat the resin material 14 in a dot shape, and it is not necessary to heat a portion other than the portion that forms the point bonding portion 24. Therefore, the cycle time until the composite 10 is obtained is shortened until the joining of the resin material 14 is completed. As a result, the composite 10 can be obtained efficiently.

  In addition, when the composite 10 is a door panel, electrodeposition coating is performed after the above-described joining process, and further, a drying process for drying the paint is performed. In this drying process, the resin material 14 is not melted. It is carried out at a temperature of about. Therefore, even after the drying step, the resin material 14 maintains a state of being joined to the workpiece 12 in a spot shape.

  Next, the composite_body | complex which concerns on 2nd Embodiment of this invention is demonstrated. The same components as those shown in FIGS. 1 and 2 are denoted by the same reference numerals, and detailed description thereof is omitted.

  In FIG. 3, the principal part longitudinal cross-sectional view of the composite_body | complex 30 which concerns on 2nd Embodiment is shown. In this case, the resin material 32 includes an elastic resin layer 34 facing the bonded surface 18 of the workpiece 12 and a reinforcing resin layer 36 provided on the elastic resin layer 34.

  As the material constituting the elastic resin layer 34, a material exhibiting excellent elasticity is selected. Moreover, it is preferable that it is excellent in weldability. Suitable examples of such materials include thermoplastic elastomers, and specific examples include styrene resins such as polystyrene resins.

  As a material constituting the reinforcing resin layer 36, the same material as that constituting the resin material 14 of the first embodiment described above can be adopted. Or the filler 38 may be contained with respect to the above-mentioned raw material. Preferable examples of the filler 38 include materials having a small specific gravity such as glass fibers and ceramic fibers. Of these, glass fiber is more preferable. By including the filler 38 in the reinforcing resin layer 36, the rigidity of the reinforcing resin layer 36 is improved.

  Further, it may be a porous body in which bubbles 40 are dispersed. In this case, due to the porous structure of the reinforcing resin layer 36, the tensile force due to the difference in thermal expansion from the work 12 is relaxed, and the occurrence of deformation can be further reduced. For example, when the resin material of the reinforcing resin layer 36 includes short fibers such as glass fibers to perform extrusion molding or press molding, the porous structure moves or bends in the resin. It can be formed by generating bubbles.

  In the resin material 32 in which the elastic resin layer 34 and the reinforcing resin layer 36 are laminated in this manner, for example, a material having excellent weldability is used as the elastic resin layer 34 so that the work material 12 and the resin material 32 are firmly formed. The rigidity of the composite 30 can be improved by using a material having excellent rigidity as the reinforcing resin layer 36 while exhibiting a bonding force.

  Also in the second embodiment, as in the first embodiment described above, the resin material 32 is disposed at a predetermined location on the bonded surface 18 of the work 12, and the plurality of locations are heated in a spot shape to perform pressure bonding. As a result, a part of the elastic resin layer 34 is welded to the bonded surface 18 of the workpiece 12.

  The welded point joint portion 24 is depressed to form a recess 26. About the heating temperature at the time of spot welding, the range to heat, the pressure of crimping | compression-bonding, etc. can be adjusted similarly to 1st Embodiment. In this case, the heating temperature may be at least heated to a temperature at which the elastic resin layer 34 can be bonded (welded) to the workpiece 12.

  When the composite 30 is a door panel, electrodeposition coating is performed after the joining step described above, and a drying step for drying the paint is further performed. In this drying process, the elastic resin layer 34 is slightly softened and is bonded to the bonded surface 18 of the workpiece 12 when solidified by being allowed to cool. That is, the elastic resin layer 34 is welded to the bonded surface 18.

  In this case, the elastic resin layer 34 is a soft body that exhibits excellent elasticity. Therefore, it easily expands / contracts following the thermal expansion / contraction of the workpiece 12. Also, it easily deforms when an external force is applied. For this reason, even if the entire workpiece-side end surface 20 of the elastic resin layer 34 is welded to the bonded surface 18, the occurrence of deformation on the workpiece 12 is avoided.

  Next, a complex 50 according to a third embodiment of the present invention will be described with reference to FIG. In this composite 50, after the resin material 14 is joined to the workpiece 12 by the same method as in the first or second embodiment, another resin material 52 is stacked so as to intersect with the resin material 14, It is obtained by arranging the material in a cross shape.

  As can be understood from the partial cross section in the longitudinal direction of the resin material 14, the resin material 14 and the resin material 52 are disposed so as to intersect at the concave portion 26 formed by the point joint portion 24 of the resin material 14. At this time, the resin material 52 can be easily disposed by accurately forming the point joint portion 24 (recess 26) of the resin material 14, and the positional accuracy of cross-layout reinforcement can be increased. Become.

  Therefore, it is preferable to set the size and position of the point joining portion 24 of the resin material 14 in accordance with the width and arrangement of another resin material 52. For example, since the close contact between the resin material 14 and the resin material 52 is increased by making the width and shape of the point joining portion 24 (recessed portion 26) correspond to the width and shape of the resin material 52, the rigidity of the composite is further increased. be able to.

  Further, as can be understood from FIG. 4, the point joining portion 54 of the resin material 52 can be provided between the adjacent resin materials 14 and 14. The rigidity of the composite 50 can be further enhanced by firmly bonding the resin material 52 to the workpiece 12. In addition to the point bonding part 54, heat may be applied to the part of the resin material 52 superimposed on the point bonding part 24 to be welded, and the resin material 14 and the resin material 52 may be bonded.

  Further, the resin material 52 in FIG. 4 is provided with a stepped portion 56 corresponding to the thickness of the point joint portion 24 at a portion straddling the resin material 14. In this way, by making the height of the step portion 56 of the resin material 52 correspond to the thickness of the point joint portion 24 of the resin material 14, the resin materials 14 and 52 are further closely adhered, and the rigidity is further improved. be able to.

  In the third embodiment, as in the second embodiment, the resin materials 14 and 52 having a layer structure including the elastic resin layer 34 and the reinforcing resin layer 36 can be used. In particular, in the case of a door panel, the whole of the work 12 and the resin materials 14 and 52 are heated by performing an electrodeposition coating and a drying process after the joining process, so that the elastic resin layer 34 and the work-side end face 20 are entirely covered with the work 12 Can be adhered to.

  The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the invention.

  For example, in the first embodiment, the resin material 14 has a linear shape (see FIG. 1), but the shape of the resin material 14 is not particularly limited thereto, and may be curved or bent. Further, when a plurality of resin materials 14 are provided, it is not particularly necessary to arrange them in parallel with each other. For example, they may be arranged in a non-parallel state such as a cross shape, a T shape, or a lattice shape.

  Furthermore, when there is a depression, a bulge, or the like on the surface to be joined 18 of the workpiece 12, the resin material 14 preferably has a depression or a bulge corresponding to the depression, the bulge, or the like. Thus, the rigidity of the composite 10 can be further improved by making the shape of the resin material 14 correspond to the shape of the bonded surface 18 of the workpiece 12.

DESCRIPTION OF SYMBOLS 10, 30, 50 ... Composite 12 ... Work piece 14, 32, 52 ... Resin material 24, 54 ... Point junction part 26 ... Recess 34 ... Elastic resin layer 36 ... Reinforcement resin layer

Claims (10)

It is a composite constructed by joining a long resin material to a workpiece made of metal,
A composite body characterized in that, at a plurality of portions of the resin material, point joint portions that are depressed toward the workpiece and are joined to the workpiece in a spot shape are formed.   2. The composite according to claim 1, wherein the resin material has a layer structure including an elastic resin layer facing the workpiece and a reinforcing resin layer positioned on the elastic resin layer.   3. The composite according to claim 1, wherein a part other than the point joint part of the resin material is joined to the workpiece.   The composite body according to any one of claims 1 to 3, wherein a plurality of the resin materials are provided, and a resin material different from the resin material is bridged between the point joint portions of the resin materials. A complex characterized in that   5. The composite according to claim 4, wherein in the another resin material, a part different from a part bridged by the point joint part of the resin material is joined to the workpiece in a spot shape. And the complex. A method of manufacturing a composite by obtaining a composite by joining a long resin material to a metal workpiece,
A composite having a step of forming a point joint portion that is depressed toward the workpiece and is joined to the workpiece in a spot shape by heating a plurality of locations of the resin material in a spot shape. Manufacturing method.   The manufacturing method according to claim 6, wherein the resin material has a layer structure including an elastic resin layer, a reinforcing resin layer, and a reinforcing resin layer positioned on the elastic resin layer. A method for producing a composite.   The manufacturing method according to claim 7, further comprising a step of bonding a portion of the resin material other than the point bonding portion to the workpiece.   The manufacturing method according to any one of claims 6 to 8, wherein a plurality of the resin materials are provided, and a resin material different from the resin material is bridged between the point joint portions of the resin materials. The manufacturing method of the composite_body | complex characterized by having.   The manufacturing method according to claim 9, further comprising a step of joining a part different from the part bridged by the point joining part of the resin material in the other resin material to the workpiece in a spot shape. A method for producing a complex.

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