JP2713225B2 - Metal forming method and metal coating method using micro ball material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal forming method and a metal coating method, and more particularly to a metal forming method and a metal coating method by bonding fine metal particles via an adhesive.

[0002]

2. Description of the Related Art Conventional metal molded products include cast products obtained by molding and casting molten cast iron or non-ferrous metal using a sand mold or a metal mold, and forging, rolling, and pressing of carbon steel and non-ferrous metal materials. Plastic processed products formed by plastic processing, cut products formed by cutting iron or non-ferrous metal materials with machine tools such as lathes, or welding processes formed by welding or cutting iron or non-ferrous metal materials by heating There are goods.

[0003] In addition, the bonding of a thin metal material has often been used for metal coating performed on an insulator for EMI measures or the like.

[0004]

The above-mentioned prior arts each have advantages and disadvantages, and a molding method suitable for the purpose has been adopted while performing economical comparison.

[0005] However, when a single product having a complicated shape is to be produced, a cast product needs to be manufactured from the production of a wooden mold or a mold, and the raw materials must be once melted.
It is costly and requires days. In the case of a plastically processed product, a press is a target, but it is necessary to manufacture a die other than a product that can be formed by simple bending or punching, which is very expensive. In cutting, precise processing is also possible, but, for example, in the case of a box-shaped product, the yield rate for the material is low, and both the material cost and the processing cost are high. In the cutting and welding by heating, a relatively complicated shape can be easily made if it is a combination of flat surfaces, but it is difficult to make a curved surface.

Further, the method of performing metal coating on an insulator by bonding a sheet metal material requires two steps of forming and bonding the sheet metal material.

An object of the present invention is to provide a molding method capable of easily and economically producing a molded article having a complicated shape even in a small number, and a coating method capable of easily performing metal coating on an insulator.

[0008]

According to the metal forming method using the microball material of the present invention, a porous metal particle formed into a small-diameter sphere is impregnated with a liquid adhesive into a void portion, and the surface of the porous metal particle is formed on the surface. A metal forming method using a microball material formed by coating a protective thin film, wherein a microball material is filled between a male mold and a female mold having a desired product shape, and the male mold and the female mold are pressed. This breaks down the porous metal particles of the microball material sandwiched between them, breaks the protective coating and combines the broken metal particles with the internal adhesive that has flowed out, forming a metal molded product of a desired shape. Let it form.

[0009] A thermosetting adhesive is used as the adhesive, the porous metal particles are broken by pressure, and after the metal particles are bonded by the adhesive, the adhesive is cured by heating to obtain a desired bonding strength. The adhesive may be a two-part adhesive, and the first
Is impregnated into the voids of the porous metal particles, and the microball material is mixed with the second liquid of the two-part adhesive, and then the porous metal particles are collapsed by applying pressure at a desired position to protect the particles. A desired bonding strength may be obtained at room temperature by contact-mixing the inner first liquid and the surrounding second liquid that have broken through the coating and bonding the metal particles with the mixed liquid. It may be a conductive adhesive.

The metal coating method using the microball material according to the present invention comprises the steps of:
This is a metal coating method using a microball material formed by impregnating a void with a liquid adhesive and coating a protective thin film on the surface. Accordingly, using a mold having a shape corresponding to the surface, a micro-ball material is arranged at substantially the same thickness, and the micro-ball material is pressed to break down the porous metal particles of the micro-ball material and break the protective coating. The disintegrated metal particles are bonded together by the adhesive that has flowed out, and the metal particles are also adhered to the surface of the object, and a metal coating of a desired shape is formed on the surface of the object by bonding the fine metal particles.

[0011] A thermosetting adhesive is used as the adhesive, the porous metal particles are broken by pressure, and after the metal particles and the object are bonded by the adhesive, the adhesive is cured by heating to obtain a desired bonding strength. The adhesive may be a two-part adhesive, and the first liquid may be impregnated into the voids of the porous metal particles,
After the microball material is mixed with the second liquid of the two-part adhesive, the porous metal particles are collapsed by applying pressure at a desired position, and the first liquid inside the protective film is broken and flows out. A desired bonding strength may be obtained at room temperature by contact-mixing the surrounding second liquid and bonding the metal particles and the object with the mixed liquid, and the adhesive may be a conductive adhesive.

[0012]

[Action] A microball material is filled between a male mold and a female mold having a desired product shape, and when both molds are pressed, the porous metal particles of the microball material sandwiched between the male mold and the female mold collapse, The metal particles are bonded by the internal adhesive that has broken through the protective coating and flowed out, and a metal molded product having a desired shape is formed.

A micro-ball material is arranged on a desired surface of the object requiring metal coating to a thickness substantially equal to that of the desired surface by using a mold having a shape corresponding to the surface, if necessary. When pressed, the porous metal particles of the microball material collapse, and the metal particles are bonded to the surface of the object by bonding with the internal adhesive that has broken through the protective coating and flown out. Is formed.

When the adhesive is a thermosetting adhesive, a desired bonding strength can be obtained by bonding the metal particles with the adhesive and then heating.

When the adhesive is a two-part adhesive, the first
Is impregnated into the voids of the porous metal particles, the microball material is mixed with the second liquid of the two-part adhesive, and then pressurized at a desired position, the porous metal particles collapse and are protected. When the first liquid inside which has broken through the coating and flows out is contact-mixed with the surrounding second liquid and the metal particles are bonded with the mixed liquid, a desired bonding strength can be obtained at room temperature.

By using a conductive adhesive as the adhesive, a molded article can have high conductivity and a metal coating can have high conductivity, which is effective for EMI measures.

[0017]

Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a front view of a microball material used in the molding method according to the first embodiment of the present invention, and FIG. 2 is a sectional view of the microball material.

1 and 2, reference numeral 10 denotes a microball material, 11 denotes porous metal particles, 12 denotes an adhesive impregnated in the voids of the porous metal particles, and 13 denotes an adhesive that prevents the adhesive from flowing out and comes into contact with air. It is a protective thin film for blocking light. A porous metal particle 1 in which submicron fine metal powder produced by a gas phase utilization method or the like is formed into a particle having a desired minute diameter by a powder metallurgy application technique used for producing a metal filter or the like.
First, a void is impregnated with a conductive liquid adhesive 12 having a thermosetting property by a vacuum impregnation method, and a protective film 13 of a synthetic polymer microencapsulated on the surface is coated to produce a microball material 10. Is done.

Next, a molding method using the microball material 10 will be described. The male and female molds of the desired product shape are made of wood, plastic or metal, etc., and the micro-ball material 10 is filled between the male and female molds whose surfaces are coated with a release agent, and both molds are pressed. The bonding of the constituent metal powders of the porous metal particles 11 of the microball material 10 sandwiched between both molds is broken, and the internal adhesive 12 breaks the protective coating 13 and flows out,
The semi-finished product is maintained in a desired shape by weakly binding the broken metal particles. Next, when the semi-finished product is heated to a temperature equal to or higher than the curing temperature of the adhesive 12, the adhesive 12 is cured and the constituent metal particles are strongly bonded to complete a metal molded product having a desired shape.

When the metal powder is formed into porous metal particles 11 having a desired minute diameter by powder metallurgy application technology, the microball material 10 is easily collapsed by adjusting the bonding force between the metal powders to be weakened. Therefore, a large strength is not required for the male mold and the female mold, and the mold can be manufactured at a low cost. The pressing force of both molds can be reduced, so that the pressing method can be simplified. Since the outer surface of the porous metal particle 11 is encapsulated by the microencapsulated protective thin film 13, the microball material can maintain a stable shape even if the bonding force is weakened.

With respect to the type of metal powder, any material that can be formed into other porous metal particles and can be bonded with an adhesive can be used, but aluminum, tungsten, and the like are noticed from ordinary applications. Also, by setting the curing temperature of the liquid adhesive to a low temperature within a range that does not cure during storage at room temperature, the temperature can be increased together with the mold having low heat resistance.

In this embodiment, a powder metallurgy application technique is used as a method for forming metal powder into porous metal particles 11 having a desired minute diameter. However, a bonding method using an adhesive medium may be used. A crushing method or a method using a sintering technique may be used. Although the vacuum impregnation method is used as a method for impregnating the gap with the liquid adhesive 12, a heating and cooling method may be used. Also,
Although the material of the protective thin film 13 is a synthetic polymer, a water-soluble protein such as gelatin or a carbohydrate such as a cellulose derivative, which is usually used for microcapsules, may be used.

Although a conductive adhesive is used in this embodiment, a non-conductive adhesive may be used if the molded article does not require conductivity.

FIG. 3 is a perspective view of an insulator metal-coated with a microball material according to a second embodiment of the present invention. The microball material 10 used in the present embodiment is
The description is omitted because it is the same as that of the embodiment.

The micro-ball material 10 is arranged on a desired surface of the plastic plate 31 which needs metal coating for EMI measures or the like to have a substantially same thickness by using a mold having a shape corresponding to the surface, if necessary. By applying pressure, the bonding of the metal powders constituting the porous metal particles 11 of the microball material 10 is broken as in the first embodiment, and the adhesive 12 inside the protective film 1
3 and flows out, weakly binds the constituent metal powders, and adheres to the surface of the plastic plate 31 to maintain a desired shape, thereby producing a semi-finished product of the metal coating 32. Next, when the semi-finished product of the metal-coated plastic plate is heated to a temperature equal to or higher than the curing temperature of the adhesive 12, the adhesive 12 is cured to bond the constituent metal powders and strongly adhere to the surface of the plastic plate 31, As a pressing method for completing the plastic plate 31 having the metal coating 32 having a desired shape, a mold may be pressed, or the exposed surface of the microball material 10 may be pressed with a metal roller or the like.

Next, a third embodiment of the present invention will be described. In the first and second embodiments, a conductive liquid adhesive having a thermosetting property is used as the adhesive 12, but in the third embodiment, a two-liquid, room temperature-curable conductive adhesive such as epoxy is used. An agent is used to impregnate the one liquid into the voids of the porous metal particles.

At the time of molding or coating, the micro-ball material 10 is mixed with another liquid of a two-part, room-temperature-curable conductive adhesive, filled in a desired place, and compressed to compress the micro-ball material 10. The bonding of the constituent metal powders of the porous metal particles 11 is broken, and one liquid of the adhesive inside breaks through the protective coating 13 and flows out, and is mixed with another liquid of the surrounding adhesive by contact,
The liquid mixture binds the constituent metal powders and adheres to the surface of the plastic plate 31 and cures at room temperature. Therefore, a heating step is not required.

[0028]

As described above, according to the molding method and the coating method using the microball material of the present invention, the bonding force between the metal powders is reduced when the metal powder is formed into porous metal particles having a desired minute diameter. Since the microball material is easily disintegrated by being adjusted to be weak, a large strength is not required for the male mold and the female mold, and the mold can be made inexpensively, and the crimping force of both molds may be small. Therefore, the pressurizing method is also simplified. In the case of coating, the force applied to the target insulator is also small.

Therefore, there is no need to melt the raw material at a high temperature as in a cast product, no need to manufacture a strong mold as in the case of plastic working by a press even with a complicated shape, and to obtain a yield on the material as in cutting. It is easy to make a curved surface that is difficult to form by cutting and welding by heating without reducing the rate, and it is possible to form a molded product of a desired shape at low cost without the need for expensive jigs and complicated processes It becomes possible.

Similarly, in forming a metal coating on an insulator, a metal coating integrated with the insulator can be easily formed.

By using a conductive adhesive as the adhesive, a molded article can have high conductivity and a metal coating can have high conductivity, which is effective for EMI measures.

Also, molding and coating can be performed at room temperature by using a two-part adhesive.

Furthermore, it is possible to easily form a material having a desired shape even with a material which is difficult to be formed by an ordinary method such as tungsten.

[Brief description of the drawings]

FIG. 1 is a front view of a microball material used in a molding method according to a first embodiment of the present invention.

FIG. 2 is a sectional view of a microball material used in the molding method according to the first embodiment of the present invention.

FIG. 3 is a perspective view of an insulator metal-coated with a microball material according to a second embodiment of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Micro ball material 11 Porous metal particle 12 Adhesive impregnated in the space of porous metal particle 13 Protective thin film for preventing outflow of adhesive and blocking contact with air 31 Metal coating 32 Plastic plate

Claims (8)

(57) [Claims] 1. A metal forming method using a micro-ball material formed by impregnating a porous adhesive with a liquid adhesive in a void portion into a porous metal particle formed into a small-diameter spherical shape and coating a protective thin film on the surface. And filling the micro-ball material between a male mold and a female mold having a desired product shape, and pressing the male mold and the female mold by pressing the micro-ball material therebetween. Microballs, wherein porous metal particles are disintegrated, and the disintegrated metal particles are bonded by the adhesive inside the protective film that has broken and flowed out to form a metal molded product having a desired shape. Metal forming method using materials. 2. The metal forming method using a microball material according to claim 1, wherein the adhesive is a thermosetting adhesive, the porous metal particles are collapsed by pressurization, and the metal is formed by the adhesive. After the grains are bonded, the adhesive is cured by heating,
A metal forming method using a microball material, wherein a desired bonding strength is obtained. 3. The metal forming method using a microball material according to claim 1, wherein the adhesive is a two-part adhesive, and a first liquid is impregnated into voids of the porous metal particles. After mixing the microball material with the second liquid of the two-part adhesive, the porous metal particles are collapsed by applying pressure at a desired position to break the protective coating, and the first part of the inside that has flowed out. Liquid and surrounding second
A metal forming method using a micro-ball material, wherein a desired bonding strength is obtained at room temperature by contact-mixing the above-mentioned liquid with the liquid and bonding the metal particles with the mixed liquid. 4. The metal molding method using a microball material according to claim 1, wherein the adhesive is a conductive adhesive. The metal forming method used. 5. A metal coating method using a microball material formed by impregnating voids with a liquid adhesive in porous metal particles formed into spherical particles having a small diameter and coating a protective thin film on the surface. The micro-ball material is disposed on a desired surface of an object requiring metal coating, if necessary, using a mold having a shape corresponding to the surface to have substantially the same thickness. The porous metal particles of the microball material are disintegrated by applying pressure, and the metal particles disintegrated by the adhesive inside the protective film that has been broken and flowed out are bonded to the surface of the object. A metal coating method using a microball material, wherein a metal particle is adhered and a metal coating of a desired shape is formed on the surface of the object by bonding the fine metal particle. 6. The metal coating method using a microball material according to claim 5, wherein the adhesive is a thermosetting adhesive, the porous metal particles are collapsed by pressurization, and the metal is applied by the adhesive. A metal coating method using a microball material, wherein after bonding the particles and the object, the adhesive is cured by heating to obtain a desired bonding strength. 7. The metal coating method using a microball material according to claim 5, wherein the adhesive is a two-part adhesive, and a first liquid is impregnated into voids of the porous metal particles. After mixing the microball material with the second liquid of the two-part adhesive, the porous metal particles are collapsed by applying pressure at a desired position,
A desired bonding strength is obtained at room temperature by contacting and mixing the first liquid inside which has flowed after breaking the protective coating with the surrounding second liquid, and bonding the metal particles and the object with the mixed liquid. A metal coating method using a microball material, characterized by being obtained. 8. The metal coating method using a micro ball material according to claim 5, wherein the adhesive is a conductive adhesive. The metal coating method used.