JP3054490B2 - Composite molding method of metal and synthetic resin and composite molded product thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite molding method of a metal and a synthetic resin and a composite molded product thereof, and more particularly, to a problem caused by an end of a film-shaped molded product being exposed at an end of the composite molded product. Regarding what has been resolved.

[0002]

2. Description of the Related Art For example, as a method of manufacturing a molded product having a smooth gas passage such as an intake manifold 1 shown in FIG. 7, a method of composite molding a metal portion such as aluminum and a synthetic resin portion has been proposed. I have. This is formed by molding a hollow film-shaped molded body made of a synthetic resin material, integrally forming a foam molded body around the film-shaped molded body to form a disappearing model, and disposing the molded body in sand. By pouring the molten metal, the foamed molded body is replaced with metal, and is integrated with the unerased film-shaped molded body by welding to obtain a composite molded article.

Incidentally, the production of the above-mentioned vanishing model has been performed by a method as shown in FIGS. The figure shows an open end of the intake manifold 1. First, there is a mold 101, and the mold 101 is an upper mold 1
03 and a lower mold 105. Upper die 10
A film-shaped molded body 109 made of a resin film is disposed in a hollow space 107 surrounded by the lower mold 3 and the lower mold 105. The film-shaped molded body 109 is supported by the baseboard 111 of the molding die 101.

In the above configuration, the space between the molding die 101 and the film-like molded body 109 is filled with foam beads 113, and the foam beads 113 are heated by steam to foam. Thereby, a vanishing model having a predetermined shape is obtained. Then, the film-shaped molded body 109 supported by the baseboard portion 111 is formed.
Is cut in accordance with the end of the foamed molded article 113 to form a vanishing model having a predetermined product shape. After that, vanishing model casting is performed using the vanishing model to obtain a composite molded product of the metal 115 and the film-shaped molded body 109 as shown in FIG.

[0005]

According to the above-mentioned conventional configuration, there are the following problems. When integrally forming the foamed molded body 113 around the film-shaped molded body 109,
The baseboard 111 is provided to support the inside of the molding die 101. For this reason, after molding, the portion of the film-like molded body 109 supported by the
Will be cut to fit the end of However, peeling may occur on the cut surface during the cutting. Further, at the time of foam molding, deformation such as wrinkles occurs in the film-like molded body due to heat, and this may appear on the cut surface. In addition, when the end 117 of the film-shaped molded body 109 as described above is exposed, the end 117 of the completed composite molded product remains even after casting.
17, the end 117 of the film-shaped molded body 109 is exposed.

Therefore, as shown in FIG. 10, a composite molded product, for example, an intake manifold 1 is connected to a cylinder head 1.
In the case of mounting on the 19, there is a problem that the gas passage is obstructed by a gap due to peeling or a thermally deformed portion. In addition, the end of the film-like molded body 109 directly hits the metal surface of the cylinder head 119 through the gasket 121, and the end of the film-like molded body 109 undergoes thermal deformation with the passage of time, thereby obstructing the gas passage. There was also.

The present invention has been made on the basis of the above points, and an object of the present invention is to provide a composite molding of a metal and a synthetic resin such that the end of the film-like molded product is not exposed at the end of the composite molded product. An object of the present invention is to provide a method and a composite molded article thereof.

[0008]

In order to achieve the above-mentioned object, a composite molding method of a metal and a synthetic resin according to the present invention is performed by integrally molding a foamed molding around a film-shaped molding made of a synthetic resin material. Forming a composite molding of a metal and a film-shaped molded product by pouring a molten metal into the metal and a synthetic resin, wherein the film-shaped molded product is disposed in a molding die, When the foamed beads are filled between the film-shaped moldings and heated to expand the foamed beads, the end of the film-shaped molding is formed shorter than the end of the composite molded product, and the supporting member is formed as the film-shaped molding. The composite molded article is supported by being inserted and inscribed in the hollow part of the above, and the end of the composite molded article is filled only with foam beads.

The composite molded article of a metal and a synthetic resin according to the present invention comprises a film-shaped molded body made of a synthetic resin material having a predetermined shape, and a predetermined shape integrally formed by welding around the film-shaped molded body. The end of the composite molded product is made of
The film-shaped formed body is characterized in that it is shorter than the above-mentioned end, and is formed so that a metal portion exists on the non-contact surface side of the film-shaped formed body with metal.

[0010]

First, in the case of the composite molding method of a metal and a synthetic resin according to the present invention, a film-like molded product is placed in a molding die, and foam beads are filled between the molding die and the film-like molded product.
When it is heated and foamed, the end of the film-shaped molded article is formed shorter than the end of the composite molded article, and the supporting member is inserted and inscribed in the hollow part of the film-shaped molded article to support the composite. The end of the molded article is filled only with foam beads, so that it is formed only of a foam molded article. When this is cast by the vanishing model casting method, it is possible to obtain a composite molded product in which the end of the film-shaped molded product is not exposed at the end. The support member may be removed after foam molding or may be removed from the product after casting.

In the composite molded article of a metal and a synthetic resin according to the present invention, the end of the composite molded article is shorter than the end of the film-shaped molded article, and the non-contact surface of the film-shaped molded article with the metal. It is formed so that there is a metal part on the side. Therefore, it is possible to prevent problems such as thermal deformation caused by exposing the end of the film-shaped molded article to the end of the composite molded article, and it is possible to firmly bond the film-shaped molded article and the metal. it can.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to FIGS. In this embodiment, the present invention is applied to the manufacture of the intake manifold 1 shown in FIG. The intake manifold 1 has a shape in which a single passage 3 having a substantially cylindrical cross section is extended, and a plurality of passages 5 are branched from the passage 3. At the end of the passage 5, a bolt mounting seat 7 is formed.
Here, it is structured to be attached to the cylinder head.

Hereinafter, the composite molding method of the present invention will be described with reference to only the end of the passage 5. First, a hollow film-shaped molded body 9 is formed. This is performed using, for example, a blow molding method, and polypropylene, polyethylene, or the like is used as a synthetic resin material. At this time,
The film-shaped molded body 9 has an inner surface shape that matches the inner surface shape of the passage 5 of the intake manifold 1, and the thickness thereof is an arbitrary thickness smaller than the thickness of the composite molded product. In addition, the end of the film-like molded body 9 is formed shorter than the end of the composite molded article.
The end of the film-shaped molded body 9 is cut in a tapered shape.
Thereby, the metal part is formed so that the metal part exists on the non-contact surface side with the metal of the film-shaped molded body after casting described later. This is to strongly bond the film-like molded body 9 with the foam molded body and eventually with the metal, and may have another end bent toward the foam molded body as another shape.

Next, the foamed molded article 1 is placed around the film-shaped molded article 9.
1 is integrally formed to form the disappearing model 13. this is,
For example, this is performed by an insert molding method, and the apparatus is shown in FIG. First, there is a molding die 15, which is composed of an upper die 17 and a lower die 19, and in the space 21 surrounded by the molding die 15,
Are accommodated and arranged. The film-shaped molded body 9 is
The support member 23 which supports the edge part of this is attached.
The support member 23 is formed by a cylinder 25 so as to be able to advance and retreat. Further, the outer peripheral portion is formed in a shape that matches the inner surface shape of the composite molded product.

When foam molding is carried out using the above-described apparatus, the film-like molded body 9 is accommodated and arranged in a space 21 surrounded by the molding die 15, and the support member 23 is attached to the film-like molded body 9
And supported at a predetermined position in the space 21. At this time, the outer peripheral portion of the support member 23 is inscribed in the inner surface of the film-shaped molded body 9. In this state, the space between the mold 15 and the film-shaped molded body 9 is filled with the foam beads 11.

Next, steam for heating is supplied into the space 21. Thereby, the expanded beads 11 are heated and expanded,
The foam molded body 11 is integrated around the film-shaped molded body 9 to complete the disappearance model 13 having a predetermined shape. The end of the disappearing model 13 is formed only of the foam molded body 11 by filling the outer peripheral portion of the support member 23 with the foam beads 1. Thereafter, the cylinder 25 is operated to pull out the support member 23 from the film-shaped molded body 11, and remove the disappearing model 13 from the molding die 1.
Remove from 5.

Next, a product is manufactured by the vanishing model casting method using the vanishing model 13. That is, a gate is attached to the vanishing model and a mold wash is applied, and the mold is placed in a flask and filled with sand. Next, the molten metal is poured through the gate. The part of the foamed molded body 11 in the disappearance model 13 disappears and is replaced with the molten metal. On the other hand, the film-like molded body 9 does not disappear, and a composite molded article 29 in which the metal 27 and the film-like molded body 9 are welded and integrated as shown in FIG. 2 is completed. The end of the composite molded article 29 is made of metal 2 as shown in the figure.
7 only. Further, a metal portion exists on the non-contact surface side of the film-shaped molded body 9 with the metal.

According to the present embodiment, the following effects can be obtained. First, at the time of foam molding, the end of the film-shaped molded article is formed shorter than the end of the composite molded article, and the supporting member is inserted and inscribed in the hollow part of the film-shaped molded article to support the composite molded article. Since only the expanded beads are filled at the end, the composite molded article 29 in which the end of the film-shaped molded body is not exposed at the end of the product can be easily manufactured.

In addition, since the end of the film-shaped molded body 9 is not exposed at the end of the composite molded article 29, problems associated with this can be solved. For example, when the present invention is applied to an intake manifold, since the end of the passage is formed only of the metal 27, the end of the film-shaped molded body 9 does not directly hit the metal surface of the cylinder head, and thermal deformation of the film-shaped molded body is reduced. Can be prevented. Further, since the metal part is formed on the non-contact surface side of the film-shaped molded body with the metal, the film-shaped molded body and the metal are firmly bonded.

Next, a second embodiment of the present invention will be described with reference to FIGS. In this case, the end of the film-shaped molded body is formed by penetrating into the flange of the intake manifold. First, as shown in FIG.
The film-shaped molded body 31 whose front end is enlarged and formed in a rectangular shape by blow molding is formed. Then, the leading end side of the film-shaped molded body 31 is partially cut to obtain the film-shaped molded body 31 shown in FIG. Next, the support member 33 is inserted into the end of the film-shaped molded body 31. In this state, foam molding is performed in a molding die (not shown) to obtain a composite molded product 37 in which the end of the film-shaped molded product is molded with the foam molded product 35 as shown in FIG.

According to this embodiment, it is possible to easily manufacture a composite molded article 37 in which the end of the film-shaped molded body is not exposed at the end of the product. In addition, since the end of the film-shaped molded body 31 is formed by casting in the flange, the end of the film-shaped molded body is not exposed at the end of the product, and the metal of the film-shaped molded body is not exposed. Since the metal portion is present on the non-contact surface side of the film, the film-shaped molded body and the metal can be more firmly bonded.

The present invention is not limited to the above embodiments. For example, as for the supporting member, besides a method of extracting the supporting member after foam molding, a material made of iron or a material obtained by molding and hardening sand is used, and casting is performed with this inserted in the foam molded body. After the molded product is completed, it may be removed or broken and removed.

[0023]

As described above in detail, according to the composite molding method of a metal and a synthetic resin according to the present invention and the molded product thereof, it is possible to easily produce a product in which the end of the film-shaped molded product is not exposed at the end of the composite molded product. The composite molded article can be manufactured. Further, the end of the film-shaped molded body is not exposed at the end, and problems associated with this, for example, troubles caused by peeling or thermal deformation of the film-shaped molded body can be prevented. In addition, the film-shaped molded body and the metal can be firmly bonded.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a molding die according to a first embodiment of the present invention.

FIG. 2 is a view showing the first embodiment of the present invention, and is a cross-sectional view showing a composite molded product.

FIG. 3 is a cross-sectional view illustrating a film-shaped molded body according to a second embodiment of the present invention.

FIG. 4 is a cross-sectional view showing a second embodiment of the present invention, in which a part of a film-shaped molded body is cut.

FIG. 5 is a view showing a second embodiment of the present invention, and is a cross-sectional view showing a state where a supporting member is inserted into a film-shaped molded body.

FIG. 6 is a view showing a second embodiment of the present invention and is a cross-sectional view showing a state in which a foamed molded body is integrated around a film-shaped molded body.

FIG. 7 is a cross-sectional view showing a part of an intake manifold formed by a conventional forming method.

FIG. 8 is a cross-sectional view showing a part of a molding die in a diagram showing a conventional molding method.

FIG. 9 is a view showing a conventional molding method and a cross-sectional view showing a part of a composite molded article.

FIG. 10 is a cross-sectional view showing a state in which an end of an intake manifold formed by a conventional forming method is attached to a cylinder head.

[Explanation of symbols]

 1 Intake manifold 3 Passage 5 Passage 9 Membrane molded body 11 Foam molded body 13 Lost model 23 Support member 27 Metal 29 Composite molded article

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ identification code FI B29L 31:00 (58) Investigated field (Int.Cl. ⁷ , DB name) B22D 19/08 B22C 7/02 103 B22D 19 / 00 B29C 44/00 B29K 105: 04 B29L 31:00

Claims (2)

(57) [Claims] 1. A composite molded article of a metal and a film-shaped molded body by integrally molding a foamed molded body around a film-shaped molded body made of a synthetic resin material to form a vanishing model and pouring a molten metal into the molded product. In the composite molding method of a metal and a synthetic resin for producing, a film-shaped molded body is arranged in a molding die, filled with foam beads between the molding die and the film-shaped molded body, and when heated to foam, The end of the film-shaped molded article is formed shorter than the end of the composite molded article, and the supporting member is inserted and inscribed in the hollow part of the film-shaped molded article to support the foamed bead. A composite molding method of a metal and a synthetic resin, characterized in that only the metal is filled. 2. A film-shaped molded product made of a synthetic resin material having a predetermined shape, and a metal having a predetermined shape integrated by welding around the film-shaped molded product. The film-shaped molded body is shorter than the above-mentioned end , and the film- shaped molded body is formed.
Shape the metal part on the non-contact side of the body with the metal.
A composite molded article of a metal and a synthetic resin, characterized in that it is formed.