JP4198675B2

JP4198675B2 - Composite molded article and manufacturing method thereof

Info

Publication number: JP4198675B2
Application number: JP2004358590A
Authority: JP
Inventors: 貴尚新美
Original assignee: 真和工業株式会社
Priority date: 2004-12-10
Filing date: 2004-12-10
Publication date: 2008-12-17
Anticipated expiration: 2024-12-10
Also published as: JP2006159862A

Description

本発明は、複合成形品とその製造方法に係り、特に、金属板の外周部に樹脂製の縁部材がインサート成形により一体成形されてなる複合成形品と、そのような複合成形品を有利に製造する方法に関するものである。 The present invention relates to a composite molded product and a method for manufacturing the same, and in particular, a composite molded product in which a resin edge member is integrally formed on the outer peripheral portion of a metal plate by insert molding, and such a composite molded product is advantageous. It relates to a method of manufacturing.

従来から、樹脂成形品の所定の部位に金属部材が埋め込まれてなる複合成形品が、インサート成形によって製造されている。そして、この複合成形品は、樹脂成形品の必要な部分に、金属部材特有の性質が付与された製品として、或いは金属部材の所定部位に、樹脂成形品の特性が具備せしめられた製品として、様々な用途に用いられてきている。 Conventionally, a composite molded product in which a metal member is embedded in a predetermined portion of a resin molded product has been manufactured by insert molding. And this composite molded product is a product in which the characteristic of the metal member is imparted to a necessary part of the resin molded product, or a product in which the characteristics of the resin molded product are provided in a predetermined part of the metal member, It has been used for various purposes.

例えば、かかる複合成形品の一種として、金属板の外周部に、その外周部の全部が埋め込まれて全周に延びる形態か、若しくは外周部の一部が埋め込まれて外周部の一個所乃至は複数個所において周方向に所定長さをもって延びる形態を呈する樹脂製の縁部材がインサート成形によって一体成形されたものがある（例えば、特許文献１参照）。このような複合成形品は、金属板部分において、優れた強度（剛性）や伝熱性乃至は放熱性、電磁波シールド性等が発揮されると共に、樹脂製の縁部材に対して、所望の取付部等が容易に成形され得るところから、例えば、高い強度が要求されるハウジングや、発熱や電磁波の発生を伴って作動せしめられる装置等が収容されるケーシングの蓋体等として、好適に使用されているのである。 For example, as a kind of such composite molded product, the outer peripheral part of the metal plate is embedded in the whole outer peripheral part and extends to the entire peripheral part, or a part of the outer peripheral part is embedded in one part or the outer peripheral part. There is one in which resin-made edge members exhibiting a form extending with a predetermined length in the circumferential direction at a plurality of locations are integrally formed by insert molding (see, for example, Patent Document 1). Such a composite molded product exhibits excellent strength (rigidity), heat transfer or heat dissipation, electromagnetic wave shielding, etc. in the metal plate portion, and has a desired mounting portion with respect to the resin edge member. Can be easily molded, for example, it is suitably used as a housing for a housing that requires high strength, a casing lid for housing a device that can be operated with generation of heat or electromagnetic waves, and the like. It is.

ところで、かくの如き金属板の外周部に樹脂製の縁部材が一体成形されてなる複合成形品においては、その配置スペースの省スペース化や軽量化等が要求される場合、金属板は勿論、樹脂製の縁部材も、薄肉とされていることが望ましい。そのため、そのような場合には、金属板の外周部のうち、縁部材の内部に埋め込まれる部分が、その内周部よりも薄くされることで、縁部材全体の薄肉化が図られている。 By the way, in a composite molded product in which a resin edge member is integrally formed on the outer peripheral portion of the metal plate as described above, when space saving or weight reduction of the arrangement space is required, of course, the metal plate, It is desirable that the resin edge member is also thin. Therefore, in such a case, the portion embedded in the edge member in the outer peripheral portion of the metal plate is made thinner than the inner peripheral portion, thereby reducing the thickness of the entire edge member. .

ところが、従来では、薄肉の縁部材を有する複合成形品を製造するに際して、先ず、打抜き等によるプレス加工により、板状金属素材から、所定の形状を有する金属板を得、次に、この金属板の外周部に対する切削加工を行って、外周部を薄肉化し、その後、かくして薄肉化された外周部に対して、樹脂製の縁部材をインサート成形により一体成形する手法が採用されている。即ち、従来手法においては、目的とする複合成形品を得るために、一つの金属板に対して、プレス加工と切削加工といった全く別の種類の加工を連続して行う必要があったのであり、それ故に、製造作業全体が非効率的で繁雑なものとなるばかりでなく、設備コストが高騰するといった問題が、不可避的に惹起されていたのである。 However, conventionally, when manufacturing a composite molded product having a thin edge member, first, a metal plate having a predetermined shape is obtained from a plate-like metal material by press working such as punching, and then this metal plate. The outer peripheral portion is cut to reduce the thickness of the outer peripheral portion, and then the resin-made edge member is integrally formed on the outer peripheral portion thus thinned by insert molding. That is, in the conventional method, in order to obtain a target composite molded product, it was necessary to continuously perform completely different types of processing such as pressing and cutting on one metal plate, Therefore, not only is the entire manufacturing operation inefficient and complicated, but also the problem of increased equipment costs has been unavoidably raised.

なお、これらの問題を解消するには、金属板の外周部を薄肉化する加工方法として、切削加工法に代えて、圧縮加工等のプレス加工法を採用することが、容易に考えられる。しかしながら、金属板の外周部を所望の厚さにまで圧縮加工して薄肉化するには、金属板の外周部に対して、極めて大きな圧縮力を加える必要があり、そうすると、プレス加工のための設備が大型化して、設備コストの低下が望まれなくなるばかりでなく、金属板に生ずる大きな応力によって、金属板全体に修復が困難な程の大きな反りが発生して、最終的に得られる複合成形品の品質が低下するといった新たな不具合が惹起されることとなるのである。 In order to solve these problems, it is easily conceivable to employ a pressing method such as compression instead of the cutting method as a processing method for thinning the outer peripheral portion of the metal plate. However, in order to compress and thin the outer peripheral portion of the metal plate to a desired thickness, it is necessary to apply a very large compressive force to the outer peripheral portion of the metal plate. Not only does the equipment increase in size and the equipment cost is not reduced, but the large stress generated on the metal plate causes a large warp that is difficult to repair on the entire metal plate. This leads to a new problem that the quality of the product deteriorates.

特開２００４−２１２４７５号公報JP 2004-212475 A

ここにおいて、本発明は、上述せる如き事情を背景にして為されたものであって、その解決課題とするところは、金属板の外周部に、樹脂製の縁部材がインサート成形により一体成形されると共に、かかる縁部材の内部に埋め込まれた部分が薄くされることで、縁部材が薄肉化されてなる複合成形品を、低コストに且つ作業効率良く、しかも優れた品質をもって製造し得る方法を提供することにある。また、本発明は、優れた製作性とコスト性とをもって、上記の如き薄肉の縁部材がインサート成形により一体成形されてなる高品質な複合成形品を提供することをも、その解決課題とするものである。 Here, the present invention has been made in the background as described above, and the problem to be solved is that a resin edge member is integrally formed by insert molding on the outer peripheral portion of the metal plate. In addition, by thinning the portion embedded in the edge member, a method of manufacturing a composite molded product in which the edge member is thinned at low cost, with high work efficiency, and with excellent quality. Is to provide. Another object of the present invention is to provide a high-quality composite molded product in which the thin edge member as described above is integrally formed by insert molding with excellent manufacturability and cost. Is.

そして、前記せる複合成形品の製造方法に係る課題の解決のために、本発明の第一の態様とするところは、金属板の外周部に、該金属板の厚さよりも薄い肉厚をもって周方向に延びる薄肉部が一体的に設けられていると共に、該薄肉部が埋め込まれた樹脂製の縁部材がインサート成形により一体成形されてなる複合成形品の製造方法であって、（ａ）前記金属板を与える金属製板状素材の外周部における周方向に間隔を開けた複数個所に、所定幅を有する切欠部を剪断加工によって設けることにより、それら複数の切欠部のうちの周方向に隣り合うもの同士の間に、該板状素材の厚さ方向に対して直角な方向となる側方に突出する板状の突部を、該隣り合う切欠部の配設間隔に応じた幅をもって一体形成して、前記金属板を得る工程と、（ｂ）該金属板の外周部に一体形成された前記突部の一方の面に対して圧縮力を作用せしめて、該一方の面側のみを圧縮変形せしめた後、該突部の他方の面に対して圧縮力を作用せしめて、該他方の面側のみを、該一方の面側の圧縮変形量よりも小さな量において圧縮変形せしめることにより、該突部に対する圧縮加工を行って、薄肉化することにより、該薄肉化された突部にて前記薄肉部を構成する工程と、（ｃ）該金属板の外周部に形成された薄肉部を所定の成形キャビティ内に配置した状態下で、所定の樹脂材料を該成形キャビティ内に導入して、インサート成形を行うことにより、該薄肉部が埋め込まれた前記縁部材を前記金属板の外周部に一体成形する工程とを含むことを特徴とする複合成形品の製造方法にある。
And, in order to solve the problem relating to the method of manufacturing a composite molded article, the first aspect of the present invention is that the outer peripheral portion of the metal plate has a thickness that is thinner than the thickness of the metal plate. thin portion extending in a circumferential direction is an integrally provided Tei Rutotomoni, composite molded method of manufacturing the edge member made of resin thin-walled portion is embedded, which are integrally formed by insert molding, (a) By providing notches having a predetermined width by shearing at a plurality of locations spaced apart in the circumferential direction on the outer periphery of the metal plate material that provides the metal plate, in the circumferential direction of the plurality of notches between adjacent groups, the plate-like projection which projects laterally as the direction perpendicular to the thickness direction of the plate-like material, with a width corresponding to the arrangement interval of notch fit Ri該隣and integrally formed, Ru obtain the metal plate step, (b And allowed exert a compressive force on one surface of the projection which is integrally formed on the outer periphery of the metal plate, after compressively deformed only one side said, with respect to the other surface of the projecting portion Applying a compressive force to compress and deform only the other surface side by an amount smaller than the amount of compressive deformation on the one surface side, thereby compressing the protrusion and reducing the thickness. O Ri, a step of forming the thin portion in the thin Nikuka been projections, under a state of arranging the thin-walled portion formed on an outer peripheral portion in a predetermined molding cavity (c) the metal plate , by introducing a predetermined resin material into the molding cavity, by performing insert molding, that comprises the step of integrally molding the edge member said thin portion is embedded in the outer peripheral portion of the metal plate It is in the manufacturing method of the composite molded article characterized.

すなわち、かかる第一の態様においては、金属板の外周部に対して剪断加工にて部分的に設けられた突部が圧縮加工されることにより、樹脂製の縁部材の内部に埋め込まれる薄肉部が形成されるものであるところから、例えば、金属板の外周部を、その全周に亘って圧縮加工して、薄肉部を形成する場合に比して、薄肉部の形成のために圧縮加工される金属板の外周部の被加工部の面積が有利に小さく為され得、それによって、薄肉部の形成に際して、金属板の被加工部に加えられる圧縮力が、十分に低く抑えられ得る。そして、その結果、プレス加工のうちの圧縮加工にて薄肉部が形成されるにも拘わらず、そのようなプレス加工のための設備の大型化が効果的に回避され得て、設備コストの増大も有利に解消され得る。また、一連のプレス加工により薄肉部が形成されるため、例えば、プレス加工と切削加工の互いに種類の異なる加工手法の両方を行う場合に生ずる製作性とコスト性の問題も、何等惹起されることもない。 That is, in the first aspect, the thin part embedded in the resin edge member by compressing the protrusion partly provided by the shearing process on the outer peripheral part of the metal plate. For example, the outer peripheral portion of the metal plate is compressed over the entire circumference to form a thin portion, compared with the case where the thin portion is formed. The area of the processed portion on the outer peripheral portion of the metal plate can be advantageously reduced, and thereby the compressive force applied to the processed portion of the metal plate can be kept sufficiently low when forming the thin-walled portion. As a result, although the thin portion is formed by the compression process among the press processes, the increase in the size of the equipment for the press process can be effectively avoided and the equipment cost is increased. Can also be advantageously eliminated. In addition, since a thin portion is formed by a series of press processing, for example, problems of manufacturability and cost that arise when performing both different types of processing methods such as press processing and cutting processing are caused. Nor.

しかも、第一の態様では、上記の如く、金属板の外周部の被加工部位（突部）に対する圧縮力が小さく抑えられ得るところから、かかる圧縮力の応力による金属板全体での反りの発生が有利に解消され得るか、若しくはそのような反りが生じても、その反り量が、その後の処理により修復が十分に可能な程度の小さな量に抑制され得るといった優れた特徴が発揮され得る。 In addition, in the first aspect, as described above, since the compressive force on the processed portion (projection) on the outer peripheral portion of the metal plate can be suppressed to be small, the warpage of the entire metal plate due to the stress of the compressive force is generated. Can be advantageously eliminated, or even if such warping occurs, an excellent feature can be exhibited in that the amount of warpage can be suppressed to a small amount that can be sufficiently repaired by subsequent processing.

また、このような本発明に従う複合成形品の製造方法においては、前記金属板の外周部に一体形成された前記突部の一方の面に対して圧縮力を作用せしめて、該一方の面側のみを圧縮変形せしめた後、該突部の他方の面に対して圧縮力を作用せしめて、該他方の面側のみを、該一方の面側の圧縮変形量よりも小さな量において圧縮変形せしめることにより、該突部に対する前記圧縮加工を行って、前記薄肉部を形成するようにされる。
Moreover, such Oite the manufacture how the composite molded articles according to the invention is caused to exert a compressive force on one surface of the projection which is integrally formed on the outer periphery of the metal plate, the one After compressing and deforming only the surface side of the projection, a compressive force is applied to the other surface of the projection so that only the other surface side is smaller than the amount of compressive deformation of the one surface side. By compressing and deforming, the thin portion is formed by performing the compression processing on the protrusion.

そして、これによって、突部の一方の面側の後に圧縮変形せしめられる突部の他方の面側を、かかる一方の面側と同等以上の量において圧縮変形せしめる場合とは異なって、例えば、一方の面側の圧縮変形により、突部全体が加工硬化（時効硬化）せしめられる場合にあっても、突部の他方の面に対して過度に大きな圧縮力を作用せしめることなく、それ故に、突部の他方の面側を損傷させるようなことなしに、容易に且つ確実に圧縮変形せしめることが出来るといった特徴が発揮される。そして、そのような突部の両面側の圧縮変形により薄肉部が形成されてなる複合成形品にあっては、例えば、金属板の外周部に対して、縁部材が、インサート成形により金属板と同じ厚さをもって一体成形される場合にも、薄肉部の両方の面側が、縁部材の内部に確実に埋め込まれ得、それによって、金属板と縁部材との接合強度が効果的に高められ得るといった利点が得られる。
Thus, unlike the case of compressing and deforming the other surface side of the projecting portion after the one surface side of the projecting portion in an amount equal to or greater than that of the one surface side, for example, Even if the entire protrusion is work-hardened (age hardening) due to the compression deformation on the surface side of the protrusion, an excessively large compressive force is not applied to the other surface of the protrusion, and therefore the protrusion The characteristic that it can be easily and reliably compressed and deformed without damaging the other surface side of the part is exhibited. And in the composite molded product in which the thin-walled portion is formed by compressive deformation on both sides of such a protrusion, for example, the edge member is inserted into the metal plate by insert molding with respect to the outer peripheral portion of the metal plate. Even when integrally molded with the same thickness, both surface sides of the thin wall portion can be securely embedded in the edge member, thereby effectively increasing the bonding strength between the metal plate and the edge member. The following advantages are obtained.

また、本発明に従う複合成形品の製造方法における第二の態様においては、前記突部における前記一方の面の全面に対して圧縮力を作用せしめて、該一方の面側を、その全面において圧縮変形せしめた後、該突部の他方の面における先端側の一部分に対して圧縮力を作用せしめて、該他方の面側の先端側部分のみを圧縮変形せしめることにより、該他方の面側の圧縮変形量が該一方の面側の圧縮変形量よりも小さくなるように、前記突部に対する圧縮加工を行うようにされる。
Further, in the second embodiment in the method of manufacturing the composite molded member according to the present invention, it brought exert a compressive force on the entire surface of the one surface of the projection, one of the side the compression in the entire After being deformed, a compressive force is applied to a portion of the other side of the protrusion on the tip side, and only the tip side portion on the other surface side is compressed and deformed, so that The protrusion is compressed so that the amount of compressive deformation is smaller than the amount of compressive deformation on the one surface side.

この第二の態様では、突部の一方の面側の後に圧縮変形せしめられる突部の他方の面側が、その先端側部分のみにおいて圧縮変形せしめられるため、突部の他方の面に作用せしめられる圧縮力の応力によって、金属板全体に反りが生ずるようなことが、有利に回避され得る。
In this second embodiment, one the other surface side of the projection to be compressively deformed after surface side of the projections, since it is compressively deformed only at its distal portion, is caused to act on the other surface of the projection It is advantageously possible to avoid warping of the entire metal plate due to the stress of the compressive force.

そして、前記せる複合成形品に係る課題の解決のために、本発明の第三の態様とするところは、金属板の外周部に、その内周部よりも薄い肉厚をもって周方向に延びる薄肉部が一体的に設けられると共に、該薄肉部が埋め込まれた樹脂製の縁部材がインサート成形により一体成形されてなる複合成形品において、前記金属板の外周部における周方向に間隔を開けた複数個所に、該金属板の厚さ方向に対して直角な方向に突出し且つ周方向に所定長さで延びる突部がそれぞれ一体形成されると共に、それら複数の突部が圧縮加工により該金属板の内周部よりも薄肉化されて、前記薄肉部が、かかる薄肉化された複数の突部により構成されていることを特徴とする複合成形品にある。
And, in order to solve the problems relating to the composite molded article, the third aspect of the present invention is that the outer peripheral portion of the metal plate has a thin wall thickness that is thinner than the inner peripheral portion and extends in the circumferential direction. In the composite molded product in which the resin edge member in which the thin portion is embedded is integrally formed by insert molding, a plurality of portions spaced apart in the circumferential direction at the outer peripheral portion of the metal plate Projections projecting in a direction perpendicular to the thickness direction of the metal plate and extending in a predetermined length in the circumferential direction are integrally formed at the respective locations, and the plurality of projections are formed by compression processing on the metal plate. The composite molded product is characterized in that it is thinner than an inner peripheral portion, and the thin portion is constituted by a plurality of thinned protrusions.

この第三の態様では、金属板の外周部に一体成形される縁部材に埋め込まれた薄肉部が、金属板の外周部に部分的に突出形成されて、圧縮加工により薄肉化された複数の突部にて構成されているところから、かかる薄肉部が切削加工により形成される場合や、金属板の外周部の全周に連続して延びるように形成される場合とは異なって、製造時の設備コストが低く抑えられる得ると共に、製造作業が効率的に行われ得、しかも、金属板全体に反りが生ずるようなことも、有利に回避され得る。
In the third embodiment, the thin portion embedded in the edge member which is integrally molded on the outer periphery of the metal plate, is partially protruded outer peripheral portion of the metal plate, a plurality of which are thinned by compression forming Unlike the case where such a thin-walled portion is formed by cutting or formed so as to extend continuously around the entire circumference of the outer peripheral portion of the metal plate, since it is constituted by a protrusion, at the time of manufacture The equipment cost can be kept low, the manufacturing operation can be performed efficiently, and warpage of the entire metal plate can be advantageously avoided.

而して、本発明に従う複合成形品の製造方法における第一の態様によれば、金属板の外周部に、樹脂製の縁部材がインサート成形により一体成形されると共に、かかる縁部材の内部に埋め込まれた部分が薄くされることで、縁部材が薄肉化されてなる複合成形品が、低コストに且つ作業効率良く、しかも反り等のない優れた品質をもって、極めて有利に製造され得ることとなるのである。 Thus, according to the first aspect of the method for manufacturing a composite molded article according to the present invention, a resin edge member is integrally formed on the outer peripheral portion of the metal plate by insert molding, and inside the edge member. By thinning the embedded portion, a composite molded product in which the edge member is thinned can be manufactured extremely advantageously at an excellent quality with low cost, high work efficiency, and no warpage. It becomes.

また、本発明に従う複合成形品の製造方法における第一の態様では、前記せる如き特徴が発揮されることで、金属板と縁部材とが高い接合強度で一体化されてなる、更に優れた品質を備えた複合成形品が、容易に且つ確実に製造され得る。
Further, in the first aspect of the method for producing a composite molded article according to the present invention, the metal plate and the edge member are integrated with high bonding strength by exhibiting the characteristics as described above, and further excellent quality. Can be manufactured easily and reliably.

さらに、本発明に従う複合成形品の製造方法における第二の態様によれば、反りのない、より面精度に優れた高品質な複合成形品が、有利に製造され得ることとなる。
Furthermore, according to the 2nd aspect in the manufacturing method of the composite molded product according to this invention, the high quality composite molded product which was excellent in surface precision without a curvature will be manufactured advantageously.

そして、本発明に従う複合成形品の第三の態様にあっては、製造時における作業の効率化と低コスト化とが有利に実現され得ると共に、反り等のない優れた品質が有利に実現され得るのである。
And, in the third aspect of the composite molded article according to the present invention, the efficiency of the work and the cost reduction during the manufacturing can be advantageously realized, and the excellent quality without warping is advantageously realized. To get.

以下、本発明を更に具体的に明らかにするために、本発明の実施の形態について、図面を参照しつつ、詳細に説明することとする。 Hereinafter, in order to clarify the present invention more specifically, embodiments of the present invention will be described in detail with reference to the drawings.

先ず、図１及び図２には、本発明に従う構造を有する複合成形品の一実施形態として、内部に所定の電子制御装置を収容して自動車のエンジンルーム内に設置される筐体状のケーシングの蓋体が、その正面形態と縦断面形態とにおいて、それぞれ概略的に示されている。それらの図から明らかなように本実施形態の複合成形品からなる蓋体１０は、金属製の天板部１２と、かかる天板部１２の外周部に一体的に設けられた樹脂製の縁部材１４とにて、構成されている。 First, in FIGS. 1 and 2, as an embodiment of a composite molded article having a structure according to the present invention, a casing-like casing that is installed in an engine room of an automobile and houses a predetermined electronic control device therein. Are respectively schematically shown in a front form and a longitudinal section form. As is clear from these drawings, the lid body 10 made of the composite molded product of the present embodiment includes a metal top plate portion 12 and a resin edge integrally provided on the outer peripheral portion of the top plate portion 12. The member 14 is constituted.

より具体的には、蓋体１０の天板部１２は、放熱性乃至は伝熱性と電磁波シールド性とにおいて優れた特性を発揮する金属材料を用いて形成された、全体として、長手矩形状を呈する所定厚さの板材からなっている。そして、かかる天板部１２の外周部には、複数の板状突部１６が、周方向に互いに間隔を開けて、一体的に突設されている。 More specifically, the top plate portion 12 of the lid 10 is formed using a metal material that exhibits excellent heat dissipation or heat transfer properties and electromagnetic wave shielding properties, and has a longitudinal rectangular shape as a whole. It consists of a plate material with a predetermined thickness. A plurality of plate-like protrusions 16 are integrally protruded from the outer peripheral portion of the top plate 12 at intervals in the circumferential direction.

すなわち、天板部１２においては、その長さ方向（図１中、左右方向）に対向位置する二つの端面のそれぞれにおける幅方向（図１中、上下方向）に間隔を開けた複数個所（例えば、ここでは三個所）に、板状突部１６が、天板部１２の長さ方向（天板部１２の厚さ方向に対して直角な方向）において、互いに同じ長さ（高さ）で突出し、且つ幅方向（天板部１２の周方向）に所定の寸法だけ延びる矩形形態をもって、一体的に設けられている。また、天板部１２の幅方向に対向位置する二つの端面のそれぞれにも、長さ方向に間隔を開けた複数個所（例えば、ここでは五個所）に、板状突部１６が、天板部１２の幅方向（天板部１２の厚さ方向に対して直角な方向）において、互いに同じ長さ（高さ）で突出し、且つ長さ方向（天板部１２の周方向）に所定の寸法だけ延びる矩形形態をもって、一体的に形成されている。 That is, in the top plate part 12, a plurality of locations (for example, the vertical direction in FIG. 1) spaced apart from each other at two end faces facing in the length direction (left and right direction in FIG. 1) (for example, In this case, the plate-like protrusions 16 have the same length (height) in the length direction of the top plate portion 12 (direction perpendicular to the thickness direction of the top plate portion 12). It is integrally provided with a rectangular shape that protrudes and extends by a predetermined dimension in the width direction (the circumferential direction of the top plate 12). In addition, plate-like protrusions 16 are provided at a plurality of locations (for example, five locations here) spaced apart in the length direction on each of the two end faces opposed to each other in the width direction of the top plate portion 12. In the width direction of the portion 12 (a direction perpendicular to the thickness direction of the top plate portion 12), the same length (height) protrudes from each other, and a predetermined amount in the length direction (the circumferential direction of the top plate portion 12) It is integrally formed with a rectangular shape that extends by the dimension.

そして、それら各板状突部１６にあっては、図２中の下面に、その全面が所定の深さだけ凹まされてなる第一凹部１８が形成されている一方、その反対側の上面には、突出方向先端側の略半分の部分が、第一凹部１８の深さの半分を下回る深さで凹まされてなる第二凹部２０が、形成されている。これによって、各板状突部１６の厚さが、天板部１２の内周部の厚さ（天板部１２自体の厚さである内側部位の厚さ）よりも、第二凹部２０の深さと第一凹部１８の深さの合計量だけ薄くされており、以て、このような薄肉の板状突部１６が、矩形のタブ状薄肉部２２とされているのである。
Each of the plate-like protrusions 16 has a first recess 18 formed on the lower surface in FIG. 2 with the entire surface being recessed by a predetermined depth, on the opposite upper surface. Is formed with a second recessed portion 20 in which a substantially half portion on the front end side in the protruding direction is recessed at a depth less than half of the depth of the first recessed portion 18. Accordingly, the thickness of each plate-like protrusion 16 is larger than the thickness of the inner peripheral portion of the top plate portion 12 (the thickness of the inner portion that is the thickness of the top plate portion 12 itself) . The total thickness of the depth and the depth of the first concave portion 18 is reduced, and thus such a thin plate-like protrusion 16 is a rectangular tab-like thin portion 22.

一方、縁部材１４は、弾性変形可能な樹脂材料を用いて形成されており、天板部１２よりも一周り大きな矩形状の全体形状と、天板部１２と同一の厚さとを有する枠部２４と、かかる枠部２４における図２中の下面に対して、一定の高さをもって一体的に突出形成された、弾性変形可能な取付脚部２６とにて、構成されている。 On the other hand, the edge member 14 is formed using an elastically deformable resin material, and has a rectangular overall shape that is slightly larger than the top plate portion 12 and has the same thickness as the top plate portion 12. 24 and an elastically deformable mounting leg portion 26 integrally formed with a certain height with respect to the lower surface in FIG. 2 of the frame portion 24.

そして、この縁部材１４の枠部２４が、その上面を天板部１２の上面と面一として、天板部１２の全周を取り囲むように位置せしめられると共に、取付脚部２６が、天板部１２の下面側に突出位置せしめられている。また、かかる枠部２４の内周面には、天板部１２の各端面における複数のタブ状薄肉部２２（板状突出部１６）の形成部位との対応部位に、穴部２８がそれぞれ設けられ、枠部２４が天板部１２を取り囲んで位置せしめられることにより、それら各穴部２８内に、タブ状薄肉部２２が突入せしめられている。そして、このような配置状態下において、枠部２４が、その内周面の全周に亘って、天板部１２の四つの端面に接合されていると共に、各穴部２８の内面の全面においても、各タブ状薄肉部２２の外面の全面に対して接合されている。 The frame portion 24 of the edge member 14 is positioned so as to surround the entire periphery of the top plate portion 12 with the upper surface thereof being flush with the upper surface of the top plate portion 12, and the mounting leg portion 26 is It protrudes from the lower surface side of the portion 12. Moreover, the hole part 28 is provided in the internal peripheral surface of this frame part 24 in the site | part corresponding to the formation site | part of the several tab-shaped thin part 22 (plate-shaped protrusion part 16) in each end surface of the top-plate part 12, respectively. Then, the frame portion 24 is positioned so as to surround the top plate portion 12, whereby the tab-like thin portion 22 is inserted into each hole portion 28. Under such an arrangement state, the frame portion 24 is joined to the four end surfaces of the top plate portion 12 over the entire inner peripheral surface thereof, and on the entire inner surface of each hole portion 28. Are joined to the entire outer surface of each tab-like thin portion 22.

かくして、ここでは、天板部１２の各タブ状薄肉部２２が、縁部材１４の枠部２４の内部に埋め込まれた状態で、換言すれば、縁部材１４の枠部２４が、天板部１２の各タブ状薄肉部２２を巻き込んだ状態で、天板部１２と縁部材１４とが一体化せしめられて、蓋体１０が、構成されている。そして、このような蓋体１０にあっては、縁部材１４の取付脚部２６が、内部に電子制御装置が収容される筐体状のケーシング（図示せず）の開口周縁部に、例えば弾性変形下で嵌合せしめられることにより、かかるケーシングに対して、その開口部を覆蓋した状態で、取り付けられるようになっている。また、そのような蓋体１０のケーシングへの取付状態下において、ケーシング内の電子制御装置の作動に伴って生ずる熱が、蓋体１０の天板部１２を通じて外部に放出せしめられる一方、外部からケーシング内への電磁波の侵入が、天板部１２にて遮断され得るようになっているのである。 Thus, here, each tab-shaped thin portion 22 of the top plate portion 12 is embedded in the inside of the frame portion 24 of the edge member 14, in other words, the frame portion 24 of the edge member 14 is connected to the top plate portion. The lid 10 is configured by integrating the top plate 12 and the edge member 14 in a state where the 12 tab-like thin portions 22 are rolled up. In such a lid 10, the mounting leg portion 26 of the edge member 14 is elastic, for example, on the opening peripheral portion of a casing-like casing (not shown) in which the electronic control device is accommodated. By being fitted under deformation, the casing is attached to the casing with its opening covered. Further, under such a state in which the lid body 10 is attached to the casing, heat generated by the operation of the electronic control device in the casing is released to the outside through the top plate portion 12 of the lid body 10, while from the outside. Intrusion of electromagnetic waves into the casing can be blocked by the top plate 12.

ところで、かくの如き構造を有する本実施形態の蓋体１０は、例えば、以下のような作業を行うことによって、有利に製造されることとなる。 By the way, the lid 10 of the present embodiment having such a structure is advantageously manufactured by performing the following work, for example.

すなわち、先ず、図３に二点鎖線で示されるような矩形の金属製板状素材３０が準備される。なお、ここで準備される金属製板状素材３０は、目的とする蓋体１０の天板部１２に要求される特性を備えた金属材料からなり、且つかかる天板部１２よりも大なる大きさを有するものであれば、その全体形状や大きさは、何等限定されるものではない。 That is, first, a rectangular metal plate-like material 30 as shown by a two-dot chain line in FIG. 3 is prepared. The metal plate material 30 prepared here is made of a metal material having characteristics required for the top plate portion 12 of the target lid 10 and is larger than the top plate portion 12. As long as it has a thickness, its overall shape and size are not limited at all.

次に、例えば、プレス成形されるべきブランクを順送りする機構を有するプレス成形機（図示せず）が用いられ、このプレス成形機に装着された抜き型にて、準備された金属製板状素材３０に対する剪断加工が行われることにより、天板部１２を与える略矩形の中間成形品３２が、かかる金属製板状素材３０から打ち抜かれて、プレス成形される。即ち、本プレス成形操作では、金属製板状素材３０に対する外形抜きにより、中間成形品３２が成形されると共に、かかる中間成形品３２の外周部における周方向（幅方向及び長さ方向）に所定の間隔を開けた複数個所に、矩形の切欠部３４が形成される。これによって、中間成形品３２の外周部における周方向に隣り合う切欠部３４同士の間に、それら切欠部３４の配設間隔に応じた幅をもって、中間成形品３２の幅方向や長さ方向にそれぞれ突出する矩形の板状突部１６が、それぞれ形成される。 Next, for example, a press molding machine (not shown) having a mechanism for progressively feeding blanks to be press-formed is used, and a metal plate-like material prepared by a punching die attached to the press-forming machine. By performing the shearing process on 30, a substantially rectangular intermediate molded product 32 that gives the top plate portion 12 is punched from the metal plate-shaped material 30 and press-molded. That is, in this press molding operation, the intermediate molded product 32 is formed by extracting the outer shape of the metal plate-shaped material 30, and predetermined in the circumferential direction (width direction and length direction) in the outer peripheral portion of the intermediate molded product 32. Rectangular cutouts 34 are formed at a plurality of positions spaced apart from each other. Thereby, between the notches 34 adjacent to each other in the circumferential direction in the outer peripheral portion of the intermediate molded product 32, the width corresponding to the arrangement interval of the notched portions 34 is set in the width direction and the length direction of the intermediate molded product 32. A rectangular plate-like protrusion 16 that protrudes from each other is formed.

その後、図４に示されるように、上記抜き型と共にプレス成形機に装着される第一の圧縮加工型３６にて、中間成形品３２の外周部に一体形成された複数の板状突部１６に対する圧縮加工が行われる。 Thereafter, as shown in FIG. 4, a plurality of plate-like protrusions 16 integrally formed on the outer peripheral portion of the intermediate molded product 32 in the first compression mold 36 mounted on the press molding machine together with the punching die. Is compressed.

ここで用いられる第一の圧縮加工型３６は、中間成形品３２よりも大きな平坦な支持面３８を有する、位置固定の固定型４０と、かかる固定型４０の支持面３８に対して接近／離隔移動可能に配置された可動型４２とを有している。また、この可動型４２は、固定型４０における支持面３８の内周部と対向位置せしめられる押えパッド４４と、かかる押えパッド４４に外挿されて、固定型４０の支持面３８の外周部と対向せしめられた状態で、押えパッド４４と相対移動可能に配置されたポンチ４６とを含んで構成されている。 The first compression mold 36 used here has a fixed support mold 40 having a flat support surface 38 larger than that of the intermediate molded product 32, and an approach / separation with respect to the support surface 38 of the fixed mold 40. And a movable mold 42 that is movably disposed. Further, the movable die 42 includes a press pad 44 that is positioned opposite to the inner peripheral portion of the support surface 38 of the fixed die 40, and an outer periphery of the support surface 38 of the fixed die 40 that is externally inserted into the press pad 44. In a state of being opposed to each other, the presser pad 44 and a punch 46 arranged to be relatively movable are included.

そして、本プレス成形操作では、図４に二点鎖線で示されるように、先ず、固定型４０の支持面３８上に中間成形体３２が載置されて、支持された状態で、可動型４２が固定型４０に接近移動せしめられることにより、それら固定型４０と可動型４２との間で、中間成形体３２が挟持される。なお、かかる挟持状態下において、中間成形品３２の外周部に一体形成された複数の板状突部１６が、可動型４２のポンチ４６に当接せしめられ、且つそれら複数の板状突部１６を除く中間成形品３２の内周部が、可動型４２の押えパッド４４に当接せしめられる。 In this press molding operation, as shown by a two-dot chain line in FIG. 4, first, the intermediate molded body 32 is placed on and supported by the support surface 38 of the fixed mold 40, and the movable mold 42. Is moved closer to the fixed mold 40, whereby the intermediate molded body 32 is sandwiched between the fixed mold 40 and the movable mold 42. Note that, in such a sandwiched state, the plurality of plate-like protrusions 16 integrally formed on the outer peripheral portion of the intermediate molded product 32 are brought into contact with the punches 46 of the movable mold 42 and the plurality of plate-like protrusions 16. The inner peripheral portion of the intermediate molded product 32 excluding the contact is brought into contact with the presser pad 44 of the movable die 42.

その後、可動型４２のポンチ４６のみが、更に固定型４０に対して接近移動せしめられることにより、中間成形品３２における複数の板状突部１６の一方の面に対して、圧縮力が、ポンチ４６にて、それぞれ作用せしめられる。これによって、図４に実線で示される如く、各板状突部１６の一方の面の全面が、凹陥するように（潰されるように）、圧縮変形せしめられて、それら各板状突部１６の一方の面に、第一凹部１８が形成される。 Thereafter, only the punch 46 of the movable mold 42 is further moved closer to the fixed mold 40, whereby a compressive force is applied to one surface of the plurality of plate-like protrusions 16 in the intermediate molded product 32. At 46, each is activated. As a result, as shown by a solid line in FIG. 4, the entire surface of one surface of each plate-like protrusion 16 is compressed and deformed so as to be recessed (smashed), and each of these plate-like protrusions 16. A first recess 18 is formed on one surface of the first.

このとき、圧縮変形せしめられる板状突部１６が、中間成形体３２の外周部に対して、互いに所定の間隔を開けて、部分的に形成されているため、例えば、中間成形体３２の外周部の全周部分を圧縮変形せしめる場合に比して、ポンチ４６にて圧縮力が作用せしめられる中間成形体３２部分の面積が十分に小さくされる。これによって、かかる圧縮力の大きさが、効果的に小さく為され得るようになる。 At this time, the plate-like protrusions 16 that are compressed and deformed are partially formed at predetermined intervals with respect to the outer periphery of the intermediate molded body 32. For example, the outer periphery of the intermediate molded body 32 Compared to the case where the entire peripheral portion of the portion is compressed and deformed, the area of the intermediate molded body 32 portion to which the compressive force is applied by the punch 46 is sufficiently reduced. As a result, the magnitude of the compression force can be effectively reduced.

しかも、本プレス成形操作では、板状突部１６の突出方向たる長さ方向の先端面と、前記切欠部３４内に露呈せしめられる幅方向の両側面とが無拘束とされた状態で、板状突部１６に対して圧縮力が作用せしめられるところから、かかる板状突部１６の圧縮変形に伴って、板状突部１６のメタル材料が、板状突部１６の長さ方向の先端面側と幅方向の両側面側とに向かって比較的にスムーズに流動せしめられるようになる。これによって、板状突部１６の基部側、即ち、中間成形体３２の内周部側へのメタル材料の流動量が可及的に少なく抑えられ得て、そのような中間成形体３２の内周部側へのメタル材料の流動に起因して、中間成形体３２の内周部で生ずる応力も、十分に小さく為され得る。そして、その結果、かかる応力により、中間成形体３２の全体に反りが発生することが、効果的に解消乃至は抑制され得るようになるのである。 In addition, in this press molding operation, the plate-like projections 16 in the lengthwise direction, ie, the protruding direction, and the widthwise side surfaces exposed in the notches 34 are unconstrained. From the point where the compressive force is applied to the protrusion 16, the metal material of the protrusion 16 is displaced in the longitudinal direction of the protrusion 16 along with the compressive deformation of the protrusion 16. It becomes possible to flow relatively smoothly toward the surface side and both side surfaces in the width direction. Thereby, the flow amount of the metal material to the base side of the plate-shaped protrusion 16, that is, the inner peripheral side of the intermediate molded body 32 can be suppressed as much as possible. Due to the flow of the metal material toward the peripheral portion, the stress generated in the inner peripheral portion of the intermediate molded body 32 can also be made sufficiently small. As a result, the occurrence of warping of the entire intermediate molded body 32 due to the stress can be effectively eliminated or suppressed.

また、ここでは、板状突部１６の圧縮変形時に、中間成形体３２の圧縮力が作用せしめられる側の面とは反対側の面が、固定型４０の平坦な支持面３８にて支持されている。そのため、かかる板状突部１６の圧縮変形に伴って、中間成形体３２の圧縮変形側とは反対側の面の平滑度が損なわれるようなこともない。 Here, when the plate-like protrusion 16 is compressed and deformed, the surface opposite to the surface on which the compression force of the intermediate molded body 32 is applied is supported by the flat support surface 38 of the fixed mold 40. ing. Therefore, along with the compression deformation of the plate-like protrusion 16, the smoothness of the surface of the intermediate molded body 32 on the side opposite to the compression deformation side is not impaired.

そして、かくして各板状突部１６の一方の面に、第一凹部１８がそれぞれ形成されたら、各板状突部１６の圧縮変形により、その先端面に形成された膨出部位が、必要に応じて、前記プレス成形機を用いた剪断加工により除去され、その後、図５に示されるように、前記抜き型や第一の圧縮加工型３６と共にプレス成形機に装着される第二の圧縮加工型４８にて、各板状突部１６の他方の面に対する圧縮加工が行われる。 Thus, when the first recess 18 is formed on one surface of each plate-like protrusion 16, the bulging portion formed on the front end surface is necessary due to the compression deformation of each plate-like protrusion 16. Accordingly, it is removed by shearing using the press molding machine, and then, as shown in FIG. 5, a second compression process that is mounted on the press molding machine together with the punching mold and the first compression processing mold 36. In the mold 48, the other surface of each plate-like protrusion 16 is compressed.

なお、ここで用いられる第二の圧縮加工型４８は、位置固定の固定型５０とそれに対して接近／離隔移動可能に対向配置された可動型５２とを有している。また、この第二の圧縮加工型４８の固定型５０においては、可動型５２との対向面が、複数の板状突部１６に第一凹部１８が設けられた中間成形体３２を支持する支持面５４とされている。そして、この支持面５４の内周部が、中間成形体３２の内周部と同じ大きさの平坦面とされている一方、その外周部には、第一凹部１８に対応した形状の段部５６が設けられている。また、可動型５２は、固定型５０の支持面５４の内周部の全面と段部５６の内周部分とに対向位置せしめられる押えパッド５８と、かかる押えパッド５８に外挿されて、固定型５０の支持面５４における段部５６の外周部分と対向せしめられた状態で、押えパッド５８と相対移動可能に配置されたポンチ６０とを含んで構成されている。 The second compression mold 48 used here has a fixed mold 50 which is fixed in position, and a movable mold 52 which is disposed so as to face the movable mold 52 so as to be able to approach / separate. Further, in the fixed mold 50 of the second compression mold 48, the surface facing the movable mold 52 supports the intermediate molded body 32 in which the first recesses 18 are provided in the plurality of plate-like protrusions 16. The surface 54 is used. And while the inner peripheral part of this support surface 54 is made into the flat surface of the same magnitude | size as the inner peripheral part of the intermediate molded body 32, the step part of the shape corresponding to the 1st recessed part 18 is formed in the outer peripheral part. 56 is provided. In addition, the movable die 52 is fixed to the presser pad 58 that is positioned opposite to the entire inner peripheral portion of the support surface 54 of the fixed die 50 and the inner peripheral portion of the stepped portion 56, and is fixed to the presser pad 58. The presser pad 58 and a punch 60 arranged to be relatively movable are configured to face the outer peripheral portion of the stepped portion 56 on the support surface 54 of the mold 50.

そして、本プレス成形操作では、図５に示される如く、中間成形体３２が、図４に示される状態から反転せしめられて、各板状突部１６の第一凹部１８を、固定型４０の支持面５４における段部５６に対応位置せしめた状態で、かかる支持面５４上に載置されて、支持される。 In this press molding operation, as shown in FIG. 5, the intermediate molded body 32 is reversed from the state shown in FIG. 4, and the first concave portion 18 of each plate-like protrusion 16 is moved to the fixed mold 40. In a state where the support surface 54 is positioned corresponding to the stepped portion 56, the support surface 54 is placed and supported on the support surface 54.

その後、図５に二点鎖線で示されるように、可動型５２が固定型５０に接近移動せしめられることにより、それら固定型５０と可動型５２との間で、中間成形体３２が挟持される。なお、かかる挟持状態下では、中間成形品３２における第一凹部１８の形成側とは反対側の面のうち、各板状突部１６の先端側略半分の部分が、可動型５２のポンチ６０に当接せしめられる一方、それら各板状突部１６の基部側略半分の部分と中間成形品３２の内周部が、可動型５２の押えパッド５８に当接せしめられる。 Thereafter, as indicated by a two-dot chain line in FIG. 5, the movable mold 52 is moved closer to the fixed mold 50, whereby the intermediate molded body 32 is sandwiched between the fixed mold 50 and the movable mold 52. . Note that, in such a sandwiched state, of the surface of the intermediate molded product 32 opposite to the side on which the first concave portion 18 is formed, the substantially half of the front end side of each plate-like protrusion 16 is the punch 60 of the movable die 52. On the other hand, approximately half of the base side of each plate-like protrusion 16 and the inner peripheral portion of the intermediate molded product 32 are brought into contact with the press pad 58 of the movable mold 52.

それに引き続いて、可動型５２のポンチ６０のみが、更に固定型５０に対して接近移動せしめられることにより、中間成形品３２における第一凹部１８の形成側とは反対側の面のうち、各板状突部１６の先端側略半分の部分に対して、圧縮力が、ポンチ６０にて、それぞれ作用せしめられる。 Subsequently, only the punch 60 of the movable mold 52 is further moved closer to the fixed mold 50, so that each of the plates on the opposite surface of the intermediate molded product 32 from the side where the first recess 18 is formed. A compressive force is applied by the punch 60 to approximately half of the tip side of the protrusion 16.

かくして、図５に実線で示される如く、各板状突部１６の第一凹部１８形成側とは反対側の面の先端側略半分の部分が、第一凹部１８よりも浅い深さで凹陥するように（潰されるように）、比較的に小さな量で圧縮変形せしめられて、それら各板状突部１６の第一凹部１８形成側とは反対側の面に、第一凹部１８よりも深さと長さとが十分に小さな第二凹部２０が形成される。そして、これによって、各板状突部１６が、中間成形体３２の内周部よりも薄肉のタブ状薄肉部２２とされ、以て、複数のタブ状薄肉部２２が外周部に一体形成された天板部１２が、プレス成形されるのである。 Thus, as shown by the solid line in FIG. 5, the substantially half of the tip side of the surface of each plate-like protrusion 16 opposite to the first recess 18 formation side is recessed at a depth shallower than the first recess 18. Thus, the plate-like projections 16 are compressed and deformed by a relatively small amount on the surface opposite to the first depression 18 forming side of each plate-like protrusion 16 than the first depression 18. A second recess 20 having a sufficiently small depth and length is formed. As a result, each plate-like protrusion 16 is formed into a tab-like thin portion 22 that is thinner than the inner peripheral portion of the intermediate molded body 32, and a plurality of tab-like thin portions 22 are integrally formed on the outer peripheral portion. The top plate 12 is press-molded.

なお、本プレス成形操作による第二凹部２０の形成時には、板状突部１６の圧縮変形量が、第一凹部１８の形成時よりも小さくされている。そのため、第一凹部１８の形成により、各板状突部１６が加工硬化（時効硬化）せしめられていても、第一凹部１８の形成時と同様な大きさの圧縮力にて、各板状突部１６に対する圧縮加工が進行せしめられるようになる。 Note that when the second recess 20 is formed by the press molding operation, the amount of compressive deformation of the plate-like protrusion 16 is made smaller than when the first recess 18 is formed. Therefore, even if each plate-like protrusion 16 is work-hardened (age hardening) due to the formation of the first recess 18, each plate-like shape is compressed with the same compressive force as when the first recess 18 is formed. The compression process for the protrusion 16 is allowed to proceed.

また、ここでは、板状突部１６の突出方向たる長さ方向の先端面と、前記切欠部３４内に露呈せしめられる幅方向の両側面とが無拘束とされた状態で、板状突部１６の先端側略半分の部分のみが圧縮変形せしめられるところから、中間成形体３２の内周部内へのメタル材料の流動が回避されるか、若しくはより一層効果的に抑制され得る。その結果、かかる板状突部１６の圧縮変形により中間成形体３２の内周部で生ずる応力によって、中間成形体３２の全体に反りが発生することが、更に一層確実に解消乃至は抑制され得るようになる。 Further, here, the plate-like protrusions in a state in which the front end surface in the length direction which is the protruding direction of the plate-like protrusions 16 and both side surfaces in the width direction exposed in the notches 34 are unconstrained. Since only the substantially half portion at the tip end side of 16 is compressed and deformed, the flow of the metal material into the inner peripheral portion of the intermediate molded body 32 can be avoided or more effectively suppressed. As a result, the occurrence of warping of the entire intermediate molded body 32 due to the stress generated in the inner peripheral portion of the intermediate molded body 32 due to the compressive deformation of the plate-like protrusions 16 can be more reliably eliminated or suppressed. It becomes like this.

さらに、本操作では、板状突部１６における第一凹部１８の形成側とは反対側の面の圧縮変形時に、中間成形体３２の内周部が、固定型５０の支持面５４における平坦な内周部において支持されているため、かかる板状突部１６の圧縮変形に伴って、中間成形体３２における第一凹部１８形成側の面の内周部の平滑度が損なわれるようなこともない。 Further, in this operation, the inner peripheral portion of the intermediate molded body 32 is flat on the support surface 54 of the fixed mold 50 when the surface of the plate-like protrusion 16 opposite to the side where the first concave portion 18 is formed is compressively deformed. Since it is supported at the inner peripheral portion, the smoothness of the inner peripheral portion of the surface on the first concave portion 18 forming side of the intermediate molded body 32 may be impaired as the plate-like protrusion 16 is compressed and deformed. Absent.

その後、必要に応じて、プレス成形された天板部１２の内周部が、固定型と可動型の平滑なプレス面間において押圧されて、かかる天板部１２の内周部の両面の平面精度が高められる。そして、それに引き続いて、天板部１２がインサート品として用いられると共に、公知の射出成形機と、図６に示される如き射出成形用金型６２とが用いられて、インサート成形が実施される。 Thereafter, if necessary, the inner peripheral portion of the press-molded top plate portion 12 is pressed between the smooth pressing surfaces of the fixed mold and the movable die, and both surfaces of the inner peripheral portion of the top plate portion 12 are flat. Accuracy is increased. Subsequently, the top plate portion 12 is used as an insert product, and insert molding is performed using a known injection molding machine and an injection mold 62 as shown in FIG.

このインサート成形操作において使用される射出成形用金型６２は、位置固定の固定型６４と、この固定型６４に対して接近／離隔移動可能に配置された可動型６６とを有している。そして、固定型６４は、可動型６６との型合せ面に、目的とする蓋体１０における縁部材１４の取付脚部２６の外形に対応した内側形状を有する固定型側キャビティ形成凹所６８が設けられている。また、この固定型６４においては、図６に明示されてはいないものの、射出成形機のノズルが接続されるスプルーブッシュの内孔とキャビティ形成凹所６８とを連通せしめるスプルーが形成されている。一方、可動型６６は、固定型６４との型合せ面に、目的とする蓋体１０のうち取付脚部２６を除く部分の外形形状、つまり天板部１２と縁部材１４の枠部２４の外形形状に対応した内側形状を有する可動型側キャビティ形成凹所７０が設けられている。 An injection molding die 62 used in this insert molding operation has a fixed die 64 that is fixed in position and a movable die 66 that is arranged so as to be able to approach / separate from the fixed die 64. The fixed mold 64 has a fixed mold side cavity forming recess 68 having an inner shape corresponding to the outer shape of the mounting leg portion 26 of the edge member 14 in the target lid body 10 on the mating surface with the movable mold 66. Is provided. Further, although not shown in FIG. 6, the fixed die 64 is formed with a sprue that allows the inner hole of the sprue bush connected to the nozzle of the injection molding machine to communicate with the cavity forming recess 68. On the other hand, the movable mold 66 is formed on the mating surface of the fixed mold 64 with the outer shape of the target lid 10 excluding the mounting leg 26, that is, the top plate 12 and the frame 24 of the edge member 14. A movable side cavity forming recess 70 having an inner shape corresponding to the outer shape is provided.

そして、本操作では、先ず、前記せるプレス成形操作によって成形された天板部１２が、固定型６４の型合せ面上に載置された状態で、固定型６４と可動型６６とが型合せされる。それにより、可動型側キャビティ形成凹所７０内に、天板部１２が収容されて、固定型６４と可動型６６との型合せ面間に、固定型側及び可動型側キャビティ形成凹所６８，７０の内面と天板部１２の外周面とにて囲まれて、天板部１２の縁部材１４の外形に対応した内側形状を有する成形キャビティ７２が形成される。 In this operation, first, the fixed mold 64 and the movable mold 66 are aligned while the top plate portion 12 formed by the press forming operation is placed on the alignment surface of the fixed mold 64. Is done. As a result, the top plate portion 12 is accommodated in the movable mold side cavity forming recess 70, and the fixed mold side and the movable mold side cavity forming recess 68 are interposed between the mating surfaces of the fixed mold 64 and the movable mold 66. , 70 and the outer peripheral surface of the top plate portion 12, a molding cavity 72 having an inner shape corresponding to the outer shape of the edge member 14 of the top plate portion 12 is formed.

その後、固定型６４の図示しないスプルーを通じて、射出成形機のノズルから射出される溶融樹脂材料７４が、成形キャビティ７２内に導入されて、充填せしめられる。そして、かかる溶融樹脂材料７４が、各タブ状薄肉部２２の両面上に巻き込んだ状態で、成形キャビティ７２内で冷却固化されることにより、縁部材１４が、天板部１２の外周部に対して、複数のタブ状薄肉部２２を枠部２４内に埋め込ませた状態で、換言すれば、各タブ状薄肉部２２の両面に接合せしめられた状態で、一体成形される。そして、その後、固定型６４と可動型６６が型開きされて、天板部１２の外周部に縁部材１２が一体成形されたインサート成形品（複合成形品）が射出成形用金型６２内から離型せしめられ、以て、図１及び図２に示される如き構造を有する、目的とする蓋体１０が得られることとなるのである。 Thereafter, the molten resin material 74 injected from the nozzle of the injection molding machine through the sprue (not shown) of the fixed mold 64 is introduced into the molding cavity 72 and filled. Then, the molten resin material 74 is cooled and solidified in the molding cavity 72 in a state where the molten resin material 74 is wound on both surfaces of each tab-shaped thin portion 22, so that the edge member 14 is in contact with the outer peripheral portion of the top plate portion 12. Thus, the plurality of tab-like thin portions 22 are integrally molded in a state where they are embedded in the frame portion 24, in other words, are joined to both surfaces of each tab-like thin portion 22. After that, the fixed mold 64 and the movable mold 66 are opened, and an insert molded product (composite molded product) in which the edge member 12 is integrally formed on the outer peripheral portion of the top plate portion 12 is formed from the inside of the injection mold 62. As a result, the target lid 10 having the structure shown in FIGS. 1 and 2 is obtained.

このように、本実施形態においては、金属製板状素材３０に対して、一種類のプレス成形機を用いたプレス成形操作を連続的に行うことによって、縁部材１４の内部に埋め込まれる複数のタブ状薄肉部２２が外周部に一体形成された天板部１２が成形される。しかも、かかるプレス成形操作において、天板部１２の外周部に互いに間隔を開けて一体形成された複数の板状突部１６を圧縮加工して、タブ状薄肉部２２を形成する際に、天板部１２（中間成形体３２）に反りが発生するようなことが確実に解消乃至は抑制されると共に、複数の板状突部１６に作用せしめられる圧縮力の大きさが、例えば、天板部１２の外周部の全周部分を圧縮加工する場合に比べて、有利に小さくされる。 As described above, in the present embodiment, the metal plate-like material 30 is continuously subjected to a press molding operation using a single type of press molding machine, whereby a plurality of embedded materials are embedded in the edge member 14. The top plate portion 12 in which the tab-like thin portion 22 is integrally formed on the outer peripheral portion is formed. Moreover, in the press molding operation, when the tab-like thin portion 22 is formed by compressing the plurality of plate-like protrusions 16 integrally formed on the outer peripheral portion of the top plate portion 12 with a space between each other, The occurrence of warpage in the plate portion 12 (intermediate molded body 32) is reliably eliminated or suppressed, and the magnitude of the compressive force that acts on the plurality of plate-like protrusions 16 is, for example, the top plate. Compared to the case where the entire peripheral portion of the outer peripheral portion of the portion 12 is subjected to compression processing, it is advantageously reduced.

従って、このような本実施形態によれば、天板部１２の外周部に、天板部１２と同一の厚さの枠部２４を有する縁部材１４がインサート成形により一体成形された蓋体１０が、例えば、切削加工や天板部１２の外周部の全周部分を圧縮加工する工程を経て作製される場合に比して、低コストに且つ作業効率良く、しかも反り等のない優れた品質をもって、極めて有利に製造され得ることとなるのである。 Therefore, according to this embodiment, the lid member 10 is integrally formed by insert molding with the edge member 14 having the frame portion 24 having the same thickness as the top plate portion 12 on the outer peripheral portion of the top plate portion 12. However, compared with the case where it is manufactured through, for example, a cutting process or a process of compressing the entire peripheral part of the outer peripheral part of the top plate part 12, it is excellent in quality with low cost, high work efficiency, and no warpage. Therefore, it can be manufactured very advantageously.

また、かかる本実施形態においては、板状突部１６に対する圧縮加工が、その一方の面側と他方の面側とにおいて、前後に分けて段階的に行われる。しかも、後から行われる板状突部１６の他方の面側に対する圧縮加工によって、かかる他方の面側の先端部分のみが、それに先立って実施される板状突部１６の一方の面側に対する圧縮加工による該一方の面側の圧縮変形量よりも小さな量で圧縮変形せしめられる。そして、それにより、板状突部１６に対して作用せしめられる圧縮力が可及的に小さくされていると共に、天板部１２の反りの発生が更に一層確実に解消乃至は抑制され得るようになっている。従って、目的とする蓋体１０の品質の更なる向上と、その製作時における作業性及び経済性の向上とが、より一層有利に実現せしめられ得る。 Moreover, in this embodiment, the compression process with respect to the plate-shaped protrusion 16 is performed stepwise in the front and back in the one surface side and the other surface side. In addition, only the tip portion on the other surface side of the plate-like protrusion 16 is compressed on the one surface side of the plate-like protrusion 16 prior to the compression process on the other surface side of the plate-like protrusion 16 performed later. It can be compressed and deformed by an amount smaller than the amount of compressive deformation on the one surface side by processing. As a result, the compressive force applied to the plate-like protrusion 16 is made as small as possible, and the occurrence of warpage of the top plate 12 can be more reliably eliminated or suppressed. It has become. Therefore, further improvement in the quality of the target lid 10 and improvement in workability and economy at the time of production can be realized even more advantageously.

加えて、本実施形態では、縁部材１４が、天板部１２の外周部に対して、各タブ状薄肉部２２の両面に接合せしめられた状態で一体成形されているため、例えば、縁部材１４と天板部１２との間に、それらの厚さ方向に過大な力が作用せしめられても、縁部材１４が天板部１２から剥離することが有利に防止され得るといった利点がある。 In addition, in this embodiment, since the edge member 14 is integrally formed with the outer peripheral portion of the top plate portion 12 being bonded to both surfaces of each tab-like thin portion 22, for example, the edge member Even if an excessive force is applied between the upper plate portion 12 and the top plate portion 12 in the thickness direction, the edge member 14 can be advantageously prevented from being separated from the top plate portion 12.

以上、本発明の具体的な構成について詳述してきたが、これはあくまでも例示に過ぎないのであって、本発明は、上記の記載によって、何等の制約をも受けるものではない。 The specific configuration of the present invention has been described in detail above. However, this is merely an example, and the present invention is not limited by the above description.

例えば、天板部１２の全体形状や、板状突部１６（タブ状薄肉部２２）の形状及び個数等は、例示のものに、何等限定されるものではない。 For example, the overall shape of the top plate 12 and the shape and number of the plate-like protrusions 16 (tab-like thin portions 22) are not limited to those illustrated.

また、前記実施形態では、複数の板状突部１６の全てのものの両面に、第一凹部１８と第二凹部２０の両方が設けられて、各板状突部１６がタブ状薄肉部２２とされていたが、それら複数の板状突部１６のうちから適宜に選択された幾つかのものだけに、第一凹部１８と第二凹部２０の両方を設ける一方、残りのものには、第一凹部１８と第二凹部２０の何れか一方だけを設けたりして、タブ状薄肉部２２を構成することも、可能である。
Moreover, in the said embodiment, both the 1st recessed part 18 and the 2nd recessed part 20 are provided in both surfaces of all the several plate-shaped protrusions 16, and each plate-shaped protrusion 16 and the tab-shaped thin part 22 are provided. However, only some of the plurality of plate-like protrusions 16 appropriately selected are provided with both the first recess 18 and the second recess 20, while the remaining and interest provided as one recess 18 only either one of the second recess 20, it is also possible to configure the tab-shaped thin portion 22.

さらに、板状突部１６に第二凹部２０を設ける場合には、その深さや長さは、板状突部１６に対して作用せしめられる圧縮力の大きさを考慮して、適宜に設定されるところである。 Furthermore, when providing the 2nd recessed part 20 in the plate-shaped protrusion 16, the depth and length are set suitably in consideration of the magnitude | size of the compression force made to act on the plate-shaped protrusion 16. FIG. It is a place.

更にまた、縁部材１４は、天板部１２のタブ状薄肉部２２が内部に埋め込まれて、インサート成形されるものであれば、必ずしも、例示される如き枠形態を有している必要はない。即ち、例えば、天板部１２の外周部のうち、互いに対向する二つの部位のそれぞれに一体形成された形態や、かかる外周部のうちの一部に部位に対して、それに沿って連続して延びるように一体形成された形態等とされていても、何等差し支えないのである。また、かかる縁部材１４の全体形状も、適宜に変更され得るものである。 Furthermore, the edge member 14 does not necessarily have to have a frame shape as illustrated as long as the tab-shaped thin portion 22 of the top plate portion 12 is embedded therein and insert-molded. . That is, for example, in the outer peripheral part of the top plate part 12, a form integrally formed with each of two parts facing each other, or a part of the outer peripheral part continuously with respect to the part Even if it is formed in an integrally formed form so as to extend, there is no problem. The overall shape of the edge member 14 can also be changed as appropriate.

加えて、前記実施形態では、本発明を、内部に所定の電子制御装置を収容して自動車のエンジンルーム内に設置される筐体状のケーシングの蓋体とその製造方法とに対して適用したものの具体例が示されていたが、本発明は、その他、金属板の外周部に、その内周部よりも薄い肉厚をもって周方向に延びる薄肉部が一体的に設けられると共に、かかる薄肉部が埋め込まれた樹脂製の縁部材がインサート成形により一体成形されてなる複合成形品とその製造方法の何れに対しても有利に適用され得るものであることは、勿論である。 In addition, in the above-described embodiment, the present invention is applied to a casing-shaped casing lid body that houses a predetermined electronic control device and is installed in an engine room of an automobile, and a manufacturing method thereof. Although the specific example of the thing was shown, the present invention is also provided with a thin portion integrally extending in the circumferential direction with a thinner thickness than the inner peripheral portion on the outer peripheral portion of the metal plate. Of course, it can be advantageously applied to any of the composite molded product in which the resin-made edge member in which is embedded is integrally formed by insert molding and the manufacturing method thereof.

その他、一々列挙はしないが、本発明は、当業者の知識に基づいて種々なる変更、修正、改良等を加えた態様において実施され得るものであり、また、そのような実施態様が、本発明の趣旨を逸脱しない限り、何れも、本発明の範囲内に含まれるものであることは、言うまでもないところである。 In addition, although not enumerated one by one, the present invention can be carried out in a mode to which various changes, modifications, improvements, etc. are added based on the knowledge of those skilled in the art. It goes without saying that all are included in the scope of the present invention without departing from the spirit of the present invention.

本発明に従う複合成形品の一実施形態としての蓋体を示す正面説明図である。It is front explanatory drawing which shows the cover body as one Embodiment of the composite molded product according to this invention. 図１におけるII−II断面説明図である。It is II-II sectional explanatory drawing in FIG. 図１に示された蓋体の製造工程の一例を説明するための図であって、剪断加工により成形された、天板部を与える中間成形品を示している。It is a figure for demonstrating an example of the manufacturing process of the cover body shown by FIG. 1, Comprising: The intermediate molded product which gives the top plate part shape | molded by the shearing process is shown. 図１に示された蓋体の製造工程の別の例を説明するための図であって、中間成形体に形成された板状突部の一方の面側を圧縮加工した状態を示している。It is a figure for demonstrating another example of the manufacturing process of the cover body shown by FIG. 1, Comprising: The state which compressed one surface side of the plate-shaped protrusion formed in the intermediate molded object is shown. . 図１に示された蓋体の図４に続く製造工程を説明するための図であって、中間成形体の板状突部における他方の面側を圧縮加工して、タブ状薄肉部を形成することにより、天板部を成形した状態を示している。FIG. 5 is a view for explaining a manufacturing process subsequent to FIG. 4 of the lid shown in FIG. 1, and compresses the other surface side of the plate-like protrusion of the intermediate molded body to form a tab-like thin portion. By doing, the state which shape | molded the top-plate part is shown. 図１に示された蓋体の図５に続く製造工程を説明するための図であって、天板部の外周部に縁部材をインサート成形している状態を示している。It is a figure for demonstrating the manufacturing process following FIG. 5 of the cover body shown by FIG. 1, Comprising: The state which insert-molds the edge member in the outer peripheral part of the top-plate part is shown.

Explanation of symbols

１０蓋体１２天板部
１４縁部材１６板状突部
１８第一凹部２０第二凹部
２２タブ状薄肉部３０金属製板状素材
３２中間成形品３４切欠部
３６第一の圧縮加工型４８第二の圧縮加工型
６２射出成形用金型７２成形キャビティ
DESCRIPTION OF SYMBOLS 10 Cover body 12 Top plate part 14 Edge member 16 Plate-shaped protrusion 18 1st recessed part 20 2nd recessed part 22 Tab-shaped thin part 30 Metal plate-shaped raw material 32 Intermediate molded product 34 Notch part 36 1st compression process type | mold 48 1st Nino compression mold 62 Injection mold 72 Molding cavity

Claims

The outer periphery of the metal plate, the thin portion is integrally provided Tei Rutotomoni, edge member made of resin thin-walled portion is embedded insert molding extending with a small wall thickness than the thickness of the metal plate in the circumferential direction A method of manufacturing a composite molded product integrally molded by
By providing notches having a predetermined width by shearing at a plurality of locations spaced apart in the circumferential direction on the outer periphery of the metal plate material that provides the metal plate, in the circumferential direction of the plurality of notches between adjacent groups, the plate-like projection which projects laterally as the direction perpendicular to the thickness direction of the plate-like material, with a width corresponding to the arrangement interval of notch fit Ri該隣and integrally formed, Ru obtain the metal plate step,
A compressive force is applied to one surface of the protrusion integrally formed on the outer peripheral portion of the metal plate, and after compressing and deforming only the one surface side, the other surface of the protrusion is applied to the other surface. Applying a compressive force to compress and deform only the other surface side by an amount smaller than the amount of compressive deformation on the one surface side, thereby compressing the protrusion and reducing the thickness. Ri by the the steps of forming the thin portion in the thin Nikuka been projections,
In a state in which the thin-walled portion formed on the outer periphery of the metal plate was placed in a predetermined mold cavity, and introducing a predetermined resin material into the molding cavity, by performing insert molding, said thin portion a step of integrally molding the edge member is embedded in the outer peripheral portion of the metal plate,
A method for producing a composite molded article comprising:

A compressive force is applied to the entire surface of the one surface of the protrusion so that the one surface side is compressed and deformed on the entire surface, and then a part of the tip side on the other surface of the protrusion is applied. By applying a compressive force and compressing and deforming only the tip side portion on the other surface side, the amount of compressive deformation on the other surface side becomes smaller than the amount of compressive deformation on the one surface side. the method of producing a composite molded article according to claim 1 to perform the compression process for the projection.

The outer periphery of the metal plate, the thin portion is integrally provided Tei Rutotomoni, edge member made of resin thin-walled portion is embedded insert molding extending with a small wall thickness than the thickness of the metal plate in the circumferential direction Into a composite molded product that is integrally molded by
A plurality of plate-like protrusions projecting in a direction perpendicular to the thickness direction of the metal plate and extending in a predetermined length in the circumferential direction are integrally formed at a plurality of circumferentially spaced locations on the outer periphery of the metal plate. And the plurality of protrusions are made thinner than the thickness of the metal plate by compression processing, and the thin part is formed by the plurality of thinned protrusions , and
The compression process for the protrusions is performed at different compressive deformation amounts on both surfaces in the thickness direction of the protrusions, each surface is recessed, and the other surface side than the recess depth on one surface side. A composite molded product characterized in that the depth of the recess is shallow .

4. The composite molded product according to claim 3, wherein the edge member has a frame portion in which the thin portion is embedded, and the thickness of the frame portion is the same as that of the metal plate.