JP2546315B2 - Composite simultaneous molding die, method of manufacturing composite material using this die, and composite material - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a mold for molding a composite material of a metal plate and a synthetic resin, a method for manufacturing the composite material using the mold, and the composite material.

[Prior Art] Conventionally, a composite material in which a resin layer is formed between two metal plates is manufactured by, for example, bonding both surfaces of a synthetic resin formed in a plate shape by extrusion with an adhesive to the metal plates. The composite material manufactured by such a method is called a so-called sandwich steel plate, and its structure is a flat plate material in which a resin layer is simply formed between metal plates and realizes various shapes such as bending and drawing. Not something to do.

Therefore, the inventors of the present application have proposed a method for producing a composite material having various shapes by combining sheet metal press working and resin injection molding (Japanese Patent Application Nos. 61-224223 and 62-62). 2113
No. 22). Specifically, a pair of punches for press processing,
Two metal plates to be molded are placed in a state of being stacked between a movable die having an uneven portion such as a die and a fixed die, and the movable die is clamped to move the die. To do. After that, while holding one metal plate in each mold, the movable mold is moved in the mold clamping release direction to form a cavity of a predetermined width between both metal plates, or a cavity is formed on the outside of the metal plate through a hole formed by pressing. Then, a molten resin is injected and injected into the cavity to form a resin layer. And
The composite material molded product is taken out after the resin layer is solidified.

[Problems to be Solved by the Invention] By the way, in the composite material manufactured according to the manufacturing method as described above, the positions, shapes, or bending shapes of the holes formed in the metal plates sandwiching the resin layer are the same. However, the degree of freedom in shape is still small.

Further, an adhesive layer is formed on the inner surface as the metal plate, for example, when using a laminated steel sheet, in the punching portion during press working, the adhesive phenomenon between the adhesive layers due to stress during shearing, heat, etc., It may be difficult to separate both metal plates.

The above-mentioned inconvenience is caused by simultaneously pressing two metal plates to be molded in a stacked state.

Therefore, an object of the present invention is to perform simultaneous press working in a state where two molded plates are separated, and to enable formation of a resin layer between both molded plates that are pressed in the separated state. Is.

[Technical Means for Solving the Problems] As technical means for solving the above problems, attention is paid to a mold for manufacturing a composite material, and as shown in (a), (b) and (c) of FIG. The first mold body 1, the second mold body 2, and the first mold body 1 and the second mold body 2 are arranged so as to be movable back and forth.
And a third mold body 3 capable of simultaneous mold clamping together with the second mold bodies 1 and 2, and for press working forming a pair on the respective facing surfaces of the first mold body 1 and the third mold body 3. Of the second mold body 2 and the third mold body 3 are formed with a pair of second concave-convex portions 5 for press work, respectively. Pressing by simultaneous clamping of each mold body with the plate 6 to be molded between the body 1 and the third mold body 3 and between the second mold body 2 and the third mold body 3, respectively. When the mold clamping is released after processing, the press-processed plates 6 are used as the first mold body 1 and the second mold body 2.
In the state where the material holders 7a and 7b respectively holding the mold surfaces of the second mold body 2 are provided in the first and second mold bodies 1 and 2, and the third mold body 3 is retracted, the molded plate When the first mold body 6 and the second mold bodies 1 and 2 in the holding state are clamped, a cavity 8 is formed between the molded plates 6 by abutting the respective mold surfaces. The injection path 10 for injecting the molten resin into the cavity 8 formed between the molded plates 6 is formed in the first or second mold body 1, 2.

Further, when it is possible to form a protruding resin layer on the outside of each molded plate 6, at least one of the first and second uneven portions 4 and 5 has a pair of punch and die, and When the first mold body 1 and the second mold body 2 in which the molded plate 6 is held are clamped with the mold body 3 of 3 retracted, the first, second, and When the third mold bodies 1, 2, 3 are simultaneously clamped, a cavity having a predetermined shape is formed which communicates with the cavity 8 between the molded plates 6 through the holes formed in the molded plates 6 by the punch and the die. The cavity forming member is provided on the mold body holding the molding target plate 6.

Furthermore, when it is possible to perform drawing on the molded plate 6, at least one of the first and second concave and convex portions 4 and 5 is located on the corresponding first or second mold body 1 or 2 side. It has a recess for resin pressure drawing.

Furthermore, as the composite material molded by the mold and method of the present invention, a pair of metal plates having through holes formed in at least one and a resin layer formed by injection molding between the pair of metal plates. And a resin layer formed integrally with the resin layer by injection molding and having a protrusion that penetrates the through hole and protrudes to the outside, a pair of metal plates and a pair of these metal plates. And a resin layer formed by injection molding between the metal plates and having a drawn portion that is bulged from the general surface of the metal plate by being drawn by the resin pressure during injection molding of the resin layer. To be

[Operation] The composite simultaneous molding die having the above-mentioned configuration and the operation will be described together with the manufacturing method.

Between the first mold body 1 and the third mold body 3 and the second mold body 2
The molded plate 6 is disposed between the first mold 3 and the third mold 3 (first
Fig. (A)), in this state, the first, second, and third mold bodies
Simultaneous mold clamping of 1,2,3. Then, the molded plate 6 arranged between the first and third mold bodies 1 and 3 is subjected to press working in a shape based on the shape of the first concavo-convex portion 4, and the second and third mold bodies are formed. The plate 6 placed between the bodies 2 and 3 is pressed by a shape based on the shape of the second concave-convex portion 5 (see FIG. 1 (b)). After that, when the mold clamping is released, each plate 6 is held by the material holders 7a and 7b on the respective mold bodies 1 and 2. In this state, the third mold body 3 is moved to the first mold body. Withdraw from between the body and the second mold 2. Then, the molded plate 6 held by the first mold body 1 and the molded plate 6 held by the second mold body 2 face each other. Then, when the first mold body 1 and the second mold body 2 are clamped, a cavity 8 is formed between the molded plates 6 by the contact of the respective mold surfaces (FIG. 1 (c)). reference). Then, when the molten resin is injected and injected into the cavity 8 through the injection path 10, a resin layer is formed between both molded plates 6.

After the resin layer is solidified, the mold clamping between the first mold body 1 and the second mold body 2 is released, and the composite molded product of the molded plate 6 and the resin is taken out.

If at least one of the first and second concave and convex portions 4 and 5 has a pair of punch and die, the above first, second and third
During the press working by simultaneously clamping the mold bodies 1, 2, and 3, the plate 6 to be molded is punched with a punch and a die. When another cavity member is provided corresponding to the punch and the die, when the molten resin is injected into the cavity 8 through the injection path 10 as described above, it is formed by the other cavity forming member through the hole. Molten resin is introduced into the cavity. As a result, the composite material molded article has a resin layer formed between the molding plates 6 and a resin layer protruding outside the hole forming position of the molding plate 6.

In the case where at least one of the first and second concave and convex portions 4 and 5 has a resin pressure reducing concave portion on the corresponding first or second mold body 1, 2 side, the above first, second, Third mold 1,
At the time of press working by simultaneous mold clamping of 2 and 3, the molding plate located in the recess for resin pressure drawing is not punched. When the molten resin is injected and injected into the cavity 8 to be formed, the injection pressure causes the plate 6 to be drawn and deformed in accordance with the shape of the recess for resin pressure drawing. As a result, the molded product of the composite material has the molded plate 6 protruding outside the position corresponding to the throttle recess in the same shape as that of the throttle recess.

[Embodiment] An embodiment of the present invention will be described below with reference to the drawings.

FIG. 2 is a diagram showing a structural example of the composite simultaneous molding die according to the present invention.

15 is a movable mold (first mold body) similar to that used in normal injection molding, 16 is the same fixed mold (second mold body), and an intermediate portion between this movable mold 15 and fixed mold 16. It has a structure in which a mold (third mold body) 17 is arranged. In the movable die 15, a punch plate 27, in which a punching punch 29 and a cavity forming tool 31 having a cavity portion 33 which also serves as a punching punch, is fixedly erected is fixed inside the die body 21, and A knockout 25 having a hole through which the punching punch 29 and the cavity forming tool 31 in the fixed state are inserted is arranged with the punch plate 27 and a gap 35. In addition, fixed type 16
A punch plate 26, in which a punch punch 28 is erected and fixed, is fixed inside the die body 22, and the punch plate 26 is further penetrated through the punch plate 26 from the back side of the die body 22 toward the die surface side. Sprue 30 for resin injection injection
Is fixed upright. Then, a knockout 24 having a hole through which the punch punch 28 and the sprue 30 are inserted is arranged via the punch plate 26 and the gap 34. On the exposed surface of the knockout 24, a resin pressure throttle recess 32 is formed. A hydraulic system is interposed in the gaps 34 and 35 formed in the mold bodies 21 and 22 of the movable mold 15 and the fixed mold 16, and the gaps of the knockouts 24 and 25 are based on the action of the hydraulic system. It is designed to move back and forth by the amount of 34,35.

As for the intermediate die 17, a die that is paired with the punch punch 29 and the cavity forming tool 31 provided in the movable die 15 is formed on the movable die 15 side of the die body 23, and also on the fixed die 16 side. Similarly, a die that is paired with the punching punch 28 and the sprue 30 provided on the fixed die 16 is formed. Further, around the die body 23, the stripper plate 37a is provided on the movable die 15 side.
However, stripper plates 37b are provided on the fixed mold 16 side, and springs are respectively arranged in the gaps 39a, 39b between the stripper plates 37a, 37b and the mold body 23 (not shown).

In the mold, metal plates 11a and 11b to be molded plates are arranged between the movable mold 15 and the intermediate mold 17 and between the fixed mold 16 and the intermediate mold 17, respectively.

 FIG. 3 is a view showing an example of the moving mechanism of the intermediate die 17.

In the figure, the movable mold 15 and the fixed mold 16 are those of a normal injection molding machine, the fixed mold 16 is fixed to the injection mechanism section 50 such as a plunger and a screw, and the movable mold 15 is operated by hydraulic pressure and the like. Thus, the mold is clamped and the mold is opened. The moving mechanism of the intermediate die 17 arranged between the movable die 15 and the fixed die 16 as described above has a roller conveyor 41 including rollers 40 sequentially arranged in the moving direction of the movable die 15 (left and right direction in the drawing). And rollers placed on the roller conveyor 41 and arranged in parallel in a direction orthogonal to the roller conveyor (vertical direction in the drawing).
The intermediate die 17 is placed on the upper roller conveyor 42. The roller conveyor 42 on which the intermediate mold 17 is directly mounted serves as a stopper and guide for the intermediate mold 17 in the mold clamping direction and as a guide when the intermediate mold 17 moves on the roller conveyor 42. A member 45 is provided.

Due to the above moving mechanism, the intermediate mold 17 has a movable mold 15 and a fixed mold 16.
When the movable mold 15 comes into contact with the intermediate mold 17 during mold clamping with
The roller conveyor 42 moves on the roller conveyor 41 integrally with the intermediate die 17, enabling simultaneous clamping of the movable die 15, the fixed die 16 and the intermediate die 17, while the intermediate die 17 is moved to the roller conveyor.
42 Move on and move between movable mold 15 and fixed mold 16 to intermediate mold
17 can be evacuated.

Next, a manufacturing process of a composite material using the composite simultaneous molding die will be described based on an operation diagram of the die shown in FIG.

Between the movable mold 15 and the intermediate mold 17, a metal plate 11 to be a molded plate
The metal plate 11b is arranged between the fixed mold 16 and the intermediate mold 17 while a is arranged (see FIG. 4 (a)). This metal plate 1
For the 1a and 11b, for example, a laminated steel plate having an adhesive film attached to the surface thereof is used, and the film surfaces thereof are set toward the intermediate mold 17, respectively. The setting method is performed, for example, by the attraction force of electromagnets provided in the stripper plates 37a and 37b.

With the metal plates 11a, 11b set as described above, the movable die 15 is moved toward the fixed die 16, and in the process, the intermediate die 17 is pushed to move the movable die 15, the fixed die 16, and the intermediate die 17. Simultaneous mold clamping is performed (see FIG. 4 (b)). At the time of this mold clamping, the metal plates 11a and 11b set as described above are pressed. Specifically, the knockouts 25 and 24 of the movable die 15 and the fixed die 16 function as plate retainers, and the knockouts 25 and 24 are punched by the punch plates 27 and 26 as the die moves.
The mold is moved by the gaps 35 and 34 between them, and the mold is completely clamped in the state where it is in contact with the punch plate. At this time,
On the movable die 15 side, punch punch 29 and cavity forming tool 31
Is protruded from the surface of the knockout 25 to make a hole corresponding to the metal plate 11a.
And the sprue 30 protrudes from the surface of the knockout 24 to make a hole corresponding to the metal plate 11b. Also, each metal plate 11
The peripheral portions of a and 11b are punched by the peripheral portion of the movable die 15 main body and the peripheral portion of the intermediate die 23, and the peripheral portion of the fixed die 16 main body and the peripheral portion of the intermediate die 23, respectively, and the stripper plate 37
Extruded by a, 37b.

As described above, when the pressing of the metal plates 11a and 11b is completed, the movable die 15 is moved in the opposite direction to the fixed die 16, and the movable die 15, the intermediate die 17, and the fixed die 15 are separated from each other. The mold is opened up to this point, and then the intermediate mold 17 is retracted in the direction perpendicular to the mold clamping direction (see FIG. 4 (c)). At this time, the processed plate 13a from the metal plate 11a is kept in close contact with the surface of the knockout 25 by the die body 21, the punching punch 29, the friction resistance at the shearing portion with the cavity forming tool 31, etc. Similarly, the processed plate 13b from the metal plate 11b is also in close contact with the surface of the knockout 24 in the mold body 22.
Retained within. Further, blank materials 14a, 14b are further provided on the stripper plates 37a, 37b of the intermediate die 17, and the movable die 15,
The punched scraps 18a, 18b and the like remain in the hole portions of the fixed die 16 corresponding to the punch punches and the like.

After retracting from the intermediate mold 17 as described above, the movable mold 15 and the fixed mold 16 are clamped (see FIG. 4 (d)). At this time, the knockouts 24, 25 are pulled to the positions of the punch plates 26, 27, and the peripheral portion of the mold body 21 of the movable mold 15 and the peripheral portion of the mold body 22 of the fixed mold 16 are brought into contact with each other so that the processed plate 13a is A cavity 38 is formed between the cavities 38 and 13b. Further, the cavity 33 of the cavity forming tool 31 is the processed plate 13a,
Another cavity communicating with the cavity 38 formed between 13b is formed. In such a state, the injection mechanism section
Molten resin injected from 50 is injected into the cavity formed as described above through the sprue 30 (dashed line arrow in FIG. 4 (d)). At the time of injecting this resin, the processed plate 13b located in the resin pressure drawing recess 32 formed in the knockout 24 of the fixed mold 16 is drawn by the resin pressure in the cavity so as to match the recess 32. When the resin is thus filled in the cavity, the processed plates 13a, 13b and the injected resin are in an adhered state by the adhesive film covering the inner surfaces of the processed plates 13a, 13b. The movable mold 15 and the fixed mold 16
At the time of mold clamping with and, the punching punch 29 on the movable die 15 side and the punching punch 28 on the fixed die 16 side are brought into a butted state to prevent the resin from flowing into that portion.

After injecting the resin as described above, after the steps of holding pressure and cooling, the movable die 15 is moved in the direction opposite to the fixed die 16 to open the die (see FIG. 4 (e)). At this time, when the knockouts 25, 24 of the molds 15, 16 are extruded by the operation of the hydraulic system, the composite material 60 having the resin layer 61 formed between the processed plates 13a, 13b is taken out. In this composite material 60, a resin protrusion 62 corresponding to the cavity 33 of the cavity forming tool 31 is formed outside the processed plate 13a, and the through hole 6 is formed at a position corresponding to the punching punches 28, 29.
3 is formed, and further, the processed plate 13b has a recess for resin pressure drawing.
A drawn portion 64 corresponding to 32 is formed.

The materials and molding conditions used by the inventor of the present application when manufacturing the composite material are as follows, for example.

Steel plate: Electrogalvanized steel plate Adhesive film: Admer film (QE305): Tohcello Chemical Co., Ltd. Resin: Nobren (AX568): Sumitomo Chemical Co., Ltd. Press pressure: About 20 tons Injection pressure: About 240 kg / cm ² Book as above According to the embodiment, even if a laminated steel sheet covered with an adhesive film is used as the plate to be molded, press processing is not performed in a state where the adhesive films are in contact with each other, so that the steel sheets overlap and the resin cannot be injected. It never becomes. In addition, the resin protrusions 62 are formed separately on the processed plate 13a side, and the drawn portions 64 are separately formed on the processed plate 13b side, so that the composite material 60 can have a more complicated shape.

The movable mold 15 and the intermediate mold 17 face each other, and the fixed mold 16
The shape of the facing surfaces of the intermediate die 17 and the intermediate die 17 is not limited to the shape corresponding to the punch and die, and the shape of each facing surface depends on the purpose of the composite material to be molded, etc. It is set arbitrarily.

The cavity forming member, which is a constituent feature of the present invention, has a cavity formed on both the movable die 15 side and the fixed die 16 side as shown in the embodiment in a state where the movable die 15 and the fixed die 16 are butted. Alternatively, it may be formed on one of the mold sides.

The injection route, which is a constituent feature of the present invention, is one in which the resin is injected by punching out the molding plate like the sprue 30 of the above embodiment, and in particular, the resin is injected from the seam side of the mold without punching the molding plate. It is also possible to inject.

Further, the present invention is not limited to the laminated steel plate as described above, but can be applied to the case of using a normal steel plate.

Furthermore, resin molding is not limited to injection molding as described above. For example, a transfer press machine is also possible.

[Effects of the Invention] As described above, according to the present invention, the two press plates are simultaneously pressed in a separated state, and the press plates can be pressed in the separated state. It becomes possible to form a resin layer on it. This makes it possible to press each plate to be molded with its own shape, increasing the degree of freedom in the shape of the composite material to be molded, and also for the plate to be covered with an adhesive film such as a laminated steel plate. The problem of inseparability disappears.

Further, the composite material of the present invention has a protruding portion integrally formed with a resin layer formed by injection molding between a pair of metal plates and a drawn portion simultaneously molded, which is high in this composite material. In addition to forming a strong protruding portion, the strength of the composite material itself can be improved by the drawn portion.

[Brief description of drawings]

FIG. 1 is a diagram showing the configuration of the present invention, FIG. 2 is a diagram showing a structural example of a composite simultaneous molding die according to the present invention, FIG. 3 is a diagram showing an example of a moving mechanism of an intermediate mold body, and FIG. FIG. 4 is a diagram showing an example of a manufacturing process of a composite material. [Explanation of Codes] 1 ... First mold body 2 ... Second mold body 3 ... Third mold body 4 ... First uneven portion 5 ... Second uneven portion 6 ... Molding Plates 7a, 7b …… Material holder 8 …… Cavity 10 …… Injection path 15 …… Movable type 16 …… Fixed type 17 …… Intermediate type 24,25 …… Knockout 26,27 …… Punch plate 28,29… … Punch punch 30 …… Sprue 31 …… Cavity forming tool

Claims (6)

(57) [Claims] 1. A first mold body (1), a second mold body (2), and a retractable arrangement between the first mold body (1) and the second mold body (2). And a third mold body (3) capable of simultaneous mold clamping together with the first and second mold bodies (1) and (2), and the first mold body (1) and the third mold body (3). ), A pair of first concave-convex portions (4) for press working are formed on each facing surface, and a pair is formed on each facing surface of the second mold body (2) and the third mold body (3). Second concave and convex portions (5) for press working are formed, respectively, between the first mold body (1) and the third mold body (3) and between the second mold body (2) and the third mold body (3). When the mold plate (6) is arranged between the mold body (3) and the mold body (3), the mold plates (6) that have been press-processed when the mold clamping is released after the press molding by simultaneous mold clamping 6) is held on the mold surfaces of the first mold body (1) and the second mold body (2), respectively. Material holder (7a) (7b)
Is provided on the first and second mold bodies (1) and (2), and the third mold body (3) is in a retracted state, and the molded plate (6) is in a holding state. Body and second mold (1)
The mold (2) and the mold surface are contacted with each other to form a cavity (8) between the molded plates (6), and the cavity (8) is formed between the molded plates (6). A composite simultaneous molding die, characterized in that an injection path (10) for injecting a molten resin into a cavity (8) is formed in the first or second mold body (1, 2). 2. The composite simultaneous molding die according to claim 1, wherein at least one of the first and second uneven portions (4,5) comprises:
A first mold body (1) and a second mold body having a pair of punches and dies, and in a state where the third mold body (3) is retracted, the molding plate (6) is in a holding state. When (2) and (3) are clamped, the punched plate and the die are used to mold the plate (6) when the first, second, and third mold bodies (1), (2), and (3) are simultaneously clamped. A cavity forming member that forms a cavity of a predetermined shape that communicates with the cavity (8) between the molded plates (6) through the holes formed in the mold is provided on the mold body holding the molded plate (6). A composite simultaneous molding die characterized by. 3. The composite simultaneous molding die according to claim 1 or 2, wherein at least one of the first and second uneven portions (4,5) is
A composite simultaneous molding die, which has a concave portion for resin pressure drawing on the corresponding first or second die body (1, 2) side. 4. A composite simultaneous mold according to any one of claims 1 to 3, which is used between a first mold body (1) and a third mold body (3) and a second mold body. A molding plate (6) is arranged between the body (2) and the third mold body (3), and in this state, the first, second, and third mold bodies (1) and (2) are placed.
(3) Simultaneous mold clamping is performed to press each plate (6) to be molded, then the mold clamping is released, and the third mold body (3) is first molded.
The first mold body (6) is retracted from the space between the mold body (1) and the second mold body (2), and then the molded plate (6) is held by the holding members (7a) and (7b). 1) and the second mold body (2) are clamped, and in that state, the molten resin is injected through the injection path (10) into the first mold body (1) and the second mold body (2). It is injected into the cavity (8) formed by the mold clamping of 2) to form a resin layer, and after the resin layer is solidified, the first mold body (1) and the second mold body (2) are separated. A method of manufacturing a composite material, comprising releasing a mold clamp and taking out a composite material molded product of a molding target plate and a resin. 5. A pair of metal plates (13a) (13b) having through holes formed in at least one side, and a pair of these metal plates (13).
resin layer (6) formed by injection molding between a) and (13b)
1), and the resin layer (61) is integrally molded with the resin layer (61) by injection molding, and has a protrusion (62) penetrating the through hole and protruding to the outside. This is a composite material. 6. A resin layer (61) having a pair of metal plates (13a) (13b) and a resin layer (61) formed by injection molding between the pair of metal plates (13a) (13b). 61) A composite material having a drawn portion (64) that is drawn by the resin pressure during injection molding and bulges from the general surface of the metal plate (13b).