JP5326452B2 - Composite structure and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a structure which is easy to produce and can maintain sealability in a joint between metal member and a resin member over a long period of time. <P>SOLUTION: The structure 1 is composed in the shape of a hollow tube by joining the metal member 10 and a second resin member 30 together through first resin members 20. The first resin members 20 are formed at both ends on the release side in the cross section of the metal member 10 formed in the shape of a semi-circular tuber through insert molding. The second resin member 30 is formed in the shape of a semi-circular tube to correspond to the metal member 10, and both ends on the release side in its cross section are joined by being welded to the respective first resin members 20 formed in metal member 10, so that a closed cross section is formed. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a composite structure in which a metal and a resin are joined, and particularly to a method for manufacturing the composite structure.

  Metal members and resin members are used in various industrial products. These metal members and resin members are properly used according to their uses and manufacturing reasons, and there are many composite structures such as parts, units, and devices that combine these.

  Conventionally, as this type of structure, for example, in Patent Document 1, a metal shell and a resin reinforcing material are reinforced so that the reinforcing material has an anchor portion penetrating a hole provided in the shell in advance. An integrated structure is disclosed by insert molding the material. In Patent Document 2, in a structure in which the inside of an opening of a metal member formed in a bowl shape is reinforced with a resin reinforcing rib, a groove is provided in a fixing portion integrally formed with the reinforcing rib, and the metal member is provided in the groove. A structure in which the open end portions of the two are engaged is disclosed.

  The structures disclosed in Patent Documents 1 and 2 achieve weight reduction as a whole by reinforcing the metal member with a resin member.

On the other hand, a metal member and a resin member may be combined in a structure that handles a fluid such as liquid or gas or a structure that requires waterproofness. In such a case, it is necessary to seal and join the metal member and the resin member between them so that fluid does not leak from the joint between the metal member and the resin member. A seal member such as packing is interposed at the joint between the resin member and the resin member.
Japanese Patent No. 2931605 JP 2003-120896 A

  However, although the techniques disclosed in Patent Documents 1 and 2 are effective when reinforcing while reducing the weight, a metal member and a resin are used to obtain a hollow structure that needs to be sealed. A complicated structure for securing a hollow portion is required in a mold for integrally molding the member, which is not practical. On the other hand, the structure in which the seal member is interposed at the joint between the metal member and the resin member can easily form a hollow structure that needs to be sealed. However, the seal member is often composed of a rubber member, and deteriorates with long-term use. For this reason, it is necessary to periodically inspect and replace the seal member during use.

  An object of the present invention is to provide a composite structure that is easy to manufacture and that can maintain a sealing property at a joint between a metal member and a resin member over a long period of time, and a method for manufacturing the same.

In order to achieve the above object, the composite structure of the present invention is a composite structure having a hollow portion formed by joining a metal member and a resin member,
A metal member having a joining end portion having an overhanging portion projecting toward the outside of the hollow portion, a first resin member formed by insert molding at the joining end portion of the metal member, and a first welded to the first resin member A second resin member, the overhanging portion has a through-hole penetrating in the thickness direction, and the first resin member is formed through the through-hole, and the first resin member is interposed between the metal member and the first resin member. The two resin members are joined to form a hollow portion.

Further, the composite structure of the present invention is a composite structure having a hollow portion formed by joining a metal member and a resin member,
A metal member having a joining end portion that has an overhanging portion projecting toward the outside of the hollow portion, a first resin member formed by insert molding on the overhanging portion of the metal member, and a second welded to the first resin member The first resin member is formed so as to cover the projecting portion, and the metal member and the second resin member are joined via the first resin member to form a hollow portion.

In the composite structure of the present invention, a closed cross section may be formed by a combination of the metal member, the first resin member, and the second resin member, and the metal member and the second resin member are tubular members. These end portions may be joined to each other.

The method for producing a composite structure of the present invention is a method for producing a composite structure having a hollow portion formed by joining a metal member and a resin member,
A step of preparing a metal member having a joint end, a step of forming a first resin member at the joint end of the metal member by insert molding, and a first resin member formed at the joint end in a desired shape And a step of welding a second resin member formed in advance to form a hollow portion.

  In the method for producing a composite structure of the present invention, preferably, the step of preparing the metal member includes forming a projecting portion projecting toward the outside of the hollow portion at the joining end portion. In this case, the step of forming the first resin member may include forming the first resin member so as to cover the protruding portion.

  According to the present invention, in a structure having a hollow portion formed by joining a metal member and a resin member, the first resin member and the second resin are joined by joining and joining the metal member and the first resin member by insert molding. A hollow structure can be easily manufactured by combining the joining with a member. And since the junction part of these members is sealed, without using sealing members, such as packing, the sealing performance of a hollow part can be maintained over a long term without a maintenance.

  Hereinafter, embodiments of the present invention will be described in detail. In the present invention, “sealing” means that the members are joined to such an extent that no gas or liquid leaks from the joint portion between the members, and the members themselves constituting the structure do not allow gas or liquid to permeate. Does not mean.

  Referring to FIG. 1, there is shown a cross-sectional view of a structure 1 according to an embodiment of the present invention having a metal member 10, two first resin members 20, and a second resin member 30. As shown in FIG. 1, the structure 1 has a substantially circular closed cross section as the metal member 10 and the second resin member 30 are joined via the first resin member 20, and It is formed in a circular tube shape having a hollow portion extending in the longitudinal direction perpendicular to the drawing.

  The metal member 10 is a semicircular tubular member having a substantially semicircular cross section, and the first resin member 20 is joined to both end portions (joint end portions) on the open side in the cross section. . The second resin member 30 is a semicircular tubular member having a substantially semicircular cross section so as to form the hollow circular tubular structure 1 in combination with the metal member 10, and the open side in the cross section thereof. It is joined to the first resin member 20 at both end portions (joint end portions). The metal member 10 is formed in advance by, for example, press molding, and the second resin member 30 is previously formed by, for example, injection molding.

  Thus, in order to obtain the structure 1 in which the metal member 10 and the second resin member 30 are joined, in the present invention, the first resin member 20 is interposed between the metal member 10 and the second resin member 30. I am letting. And the 1st resin member 20 has a property compatible with the 2nd resin member 30, and while joining with the metal member 10 by insert molding, it joins with the 2nd resin member 30 by welding. . Accordingly, the structure 1 is configured as a hollow tube having a substantially circular closed cross section.

  When the metal member 10 and the second resin member 30 are joined via the first resin member 20, the metal member 10 and the first resin member 20 are securely joined, and the first resin member 20 and the second resin member are joined. It is important that 30 is securely joined. Therefore, this embodiment has the following configuration as a preferable configuration.

  An overhang portion 11 is uniformly formed over the entire length of the metal member 10 at the joint end portion of the metal member 10. The projecting portion 11 is formed so as to project toward the outside of the hollow portion of the structure 1, in other words, toward the radially outer side of the metal member 10.

  The first resin member 20 is fixed to the metal member 10 to such an extent that the first resin member 20 does not easily fall off from the metal member 10, and a joining surface 21 that faces the joining end of the second resin member 30 is formed over the entire length of the metal member 10. Are formed in such a size and shape. In particular, in this embodiment, the first resin member 20 is formed in a shape that covers the protruding portion 11 of the metal member 10 except for both end surfaces in the longitudinal direction.

  The second resin member 30 is integrally formed with an overhang portion 31 having a joint surface 32 facing the joint surface 21 of the first resin member 20 on the joint end surface thereof. The joint surface 32 of the second resin member 30 is joined by welding.

  Next, a method for manufacturing the structure 1 described above will be described.

  First, the metal member 10 formed in a desired shape by press molding or the like is prepared. In this embodiment, the metal member 10 is formed so as to have the protruding portion 11.

  Next, the prepared metal member 10 is set in a mold for insert molding, and the first resin member 20 is formed on the protruding portion 11 of the metal member 10 by insert molding.

  After insert molding of the first resin member 20, the second resin member 30 formed in a desired shape in advance is welded to the first resin member 20. The second resin member 30 is welded by bringing the joint surface 32 of the overhang portion 31 into close contact with the joint surface 21 of the first resin member 20. For welding of the first resin member 20 and the second resin member 30, any welding technique such as laser welding or vibration welding can be used.

  As described above, the structure 1 of this embodiment is manufactured.

  The type of metal constituting the metal member 10 is not particularly limited, and various metals such as iron and aluminum can be used according to the use of the structure 1, the performance required for the metal member 10, and the like.

  There is no restriction | limiting in particular in resin used for the 1st resin member 20 and the 2nd resin member 30, Arbitrary resin can be used according to the characteristic and shaping | molding required for each member.

  Preferred resins used for the first resin member 20 and the second resin member 30 include, for example, polyamide resin, polyacetal resin, polycarbonate resin, polyether resin, polyester resin, polypropylene, and ABS resin. These resins may be used alone or in combination of two or more. Particularly preferred resins when used alone include polyamide resins and polypropylene. Specific examples of the polyamide resin include aliphatic polyamides such as nylon 6, nylon 66, nylon 11 and nylon 12, and semi-aromatic polyamide resins such as polyhexamethylene terephthalamide and polyhexamethylene isophthalamide. Can be mentioned. These resins may consist of one or two or more copolymers. Among the polyamide resins, nylon 6 and nylon 66 are preferable.

  However, since the first resin member 20 and the second resin member 30 are joined to each other by welding, the combination of the resin used for the first resin member 20 and the resin used for the second resin member 30 is a compatible resin. Any combination is possible as long as they are combined, and different resins can be combined, but preferably both are the same resin. The term “compatible with each other” means that the difference in solubility parameter between one resin and the other resin is small, specifically 1.4 or less, preferably 1.2 or less, more preferably 1 0 or less, which means that both molecular chains can be mixed. Here, the solubility parameter (Sp) value is calculated from the polymer skeleton by the method of Fedors (see documents such as R. F. Fedors, Poly. Eng. And Sci., 14 (2), 147 (1974)). The

  The 1st resin member 20 and the 2nd resin member 30 can also be comprised with the fiber reinforced resin reinforced with glass fiber, carbon fiber, etc., Especially the glass fiber reinforced nylon 6 can be used preferably. When using fiber reinforced resin, both the 1st resin member 20 and the 2nd resin member 30 can also be formed with fiber reinforced resin, and any one can also be formed with fiber reinforced resin. When only one of the first resin member 20 and the second resin member 30 is formed of fiber reinforced resin, the first resin member 20 is formed of resin that is not fiber reinforced, and the second resin member 30 is formed of fiber reinforced resin. It is preferable to do. By so doing, the first resin member 20 can absorb the difference in thermal expansion between the metal member 10 and the second resin member 30 that accompanies a temperature change during the manufacture of the structure 1 or in the environment in which the structure 1 is used. it can.

  In the structure 1 of the present embodiment, the metal member 10 and the first resin member 20 are closely bonded to each other by insert molding, and the first resin member 20 and the second resin member 30 are welded to each other and bonded. Has been. Therefore, the sealing performance at the joint between the metal member 10 and the first resin member 20 and the joint between the first resin member 20 and the second resin member 30 in the hollow portion of the structure 1 configured in a hollow circular tube. Is secured. Therefore, the structure 1 of this embodiment can be suitably used for a component or unit for circulating a fluid such as gas or liquid therein, or a component or unit that requires waterproofness. In addition, since a sealing member such as packing is not required to ensure this sealing performance, the structure is simple and the sealing performance can be maintained for a long period of time without maintenance.

  In addition, as described above, a structure having a hollow portion defined by the inner surfaces of the metal member and the resin member is produced by combining the insert molding of the resin member with the metal member and welding the resin members together. The body 1 can be manufactured very easily. On the other hand, when an attempt is made to produce a structure in which the hollow portion is defined on the inner surface of the metal member and the resin member only by insert molding, a structure for forming the hollow portion in the mold for insert molding This requires not only a complicated mold structure, but also a complicated molding process.

  Since the first resin member 20 is insert-molded with respect to the metal member 10, the metal member 10 and the first resin member 20 are merely mechanically intimately bonded and chemically bonded. Absent. That is, the first resin member 20 is merely held by the metal member 10 with a mechanical structure. And the 1st resin member 20 is formed in the overhang | projection part 11 formed uniformly in the longitudinal direction of the metal member 10 except for the longitudinal direction both end surfaces of the metal member 10. Therefore, in the structure 1 of this embodiment, if the metal member 10 and the second resin member 30 are slid in the opposite directions along the longitudinal direction of the structure 1, the metal member 10 is moved to the remaining first. The resin member 20 and the second resin member 30 can be separated. Therefore, when the structure 1 is discarded, the metal and the resin can be easily separated.

  Furthermore, the structure 1 has the following specific effects according to the overall configuration and the like. For example, when the structure 1 is obtained by replacing a part of a component that is conventionally made of metal with a resin, the weight can be reduced as compared with the conventional case. When the structure 1 is a metal semicircular tubular member added with a resin member, the opening of the metal semicircular tubular member can be reinforced by the resin member. Thus, by reinforcing with a resin member, an increase in weight can be suppressed as compared with the case of reinforcing with a metal.

  In the embodiment described above, the hollow tubular structure 1 is shown, but the cross-sectional shape of the structure 1 is not limited to this. Moreover, the ratio of the length of the metal member 10 and the second resin member 30 in the circumferential direction of the structure 1 is not limited to the above-described embodiment. These include parts that require high dimensional accuracy, parts that require electrical conductivity, or parts that need to incorporate other mechanical elements such as valves, and other parts that are made of resin. Depending on the function required depending on the portion of the structure 1, the metal constituting the metal member 10, the resin constituting the second resin member 30, and the like can be determined as appropriate.

  An example of a structure having a changed cross-sectional shape is shown in FIG. In the form shown in FIG. 2, the structure 1 has a hollow tube structure with a rectangular cross section. The metal member 10 has a substantially U-shaped cross section, and overhang portions 11a are formed at both ends on the open side. The second resin member 30 is a flat plate-like member, which is joined to the first resin member 20 that is insert-molded in the protruding portion 11a of the metal member 10, whereby the structure 1 is a hollow having a substantially rectangular closed cross section. Tubular.

  The structure 1 shown in FIG. 2 can also be manufactured in the same manner as the structure 1 shown in FIG. That is, the metal member 10 and the second resin member 30 formed in a desired shape are prepared in advance, the first resin member 20 is joined to the prepared metal member 10 by insert molding, and then the first resin member 20 is formed. And the second resin member 30 are joined by welding.

  In the form shown in FIG. 1, the protruding portion 11 of the metal member 10 is formed to extend straight outward in the radial direction of the metal member 10. In this case, it is conceivable that the first resin member 20 comes off from the overhanging portion 11 when a force toward the radially outer side of the metal member 10 acts on the first resin member 20. However, in the form shown in FIG. 2, the overhanging portion 11a is formed in a shape bent toward the second resin member 30 at the intermediate portion, and the first resin member 20 is formed covering the overhanging portion 11a of such a shape. Therefore, even if the above-described force is applied to the first resin member 20, the first resin member 20 does not come out of the protruding portion 11a. However, as long as the overhanging portion 11a is uniformly formed in the longitudinal direction of the structure 1 even in such a shape, when the structure 1 is discarded, a metal is disposed in the same manner as the embodiment shown in FIG. And resin can be separated.

  The overhanging portion 11 formed on the metal member 10 is not an essential component in the present invention, and the metal member 10 that is not subjected to any processing at the joining end portion where the first resin member 20 is insert-molded may be used. Good. However, in order to securely hold the first resin member 20 having the bonding surface 21 having a size necessary for obtaining sufficient bonding strength with the second resin member 30 at the end of the metal member 10, It is preferable that the overhang portion 11 is formed.

  The form of the joint between the metal member 10 and the first resin member 20 is required between the metal member 10 and the first resin member 20 in addition to the form shown in FIG. 1 and the form shown in FIG. Various forms can be adopted in consideration of the bonding strength, the separability at the time of disposal of the structure 1, and the like. Some examples are shown in FIGS. 3A-3D.

  In the example shown in FIG. 3A, the direction of bending in the middle of the overhanging portion 11b is opposite to the example shown in FIG. That is, the overhanging portion 11 b is bent in the direction of making a U-turn at the joining end portion of the metal member 10. In this case, in addition to the same effect as the overhanging portion 11a shown in FIG. 2, the distance between the metal member 10 excluding the overhanging portion 11b and the second resin member 30 is made smaller than in the example shown in FIG. As a result, the structure 1 can be configured more compactly.

  In the example shown in FIG. 3B, the overhanging portion 11c has a through-hole 12 that penetrates in the thickness direction and opens on the outer end surface of the overhanging portion 11c. FIG. 3B1 shows a view of the protruding portion 11c as seen from the side to which the second resin member is joined in order to more clearly show the shape of the through hole 12. By providing such a through hole 12, the first resin member 20 covering the overhanging portion 11 c is formed so as to fill the through hole 12 of the overhanging portion 11 c and penetrate the through hole 12. By providing the through-hole 12, the metal member 10 and the first resin member 20 cannot be separated even if they are slid in the opposite directions along the longitudinal direction of the metal member 10, but the first resin member By pulling 20 toward the outside of the metal member 10 (in the direction of arrow A), the two can be separated. In such a configuration, the first resin member 20 is held by the overhanging portion 11c in a state of being snap-fitted to the through hole 12, so that the first resin member 20 can be formed by appropriately designing the shape of the through hole 12. The force required to separate can be arbitrarily adjusted.

  The number of the through holes 12 can be determined according to the length of the structure, and may be one or plural. When the plurality of through holes 12 are provided, the intervals may be constant or irregular, but it is preferable to disperse them in the longitudinal direction of the protruding portion 11c as much as possible.

  In the example shown in FIG. 3C, the overhanging portion 11 d has a through hole 13 that penetrates only in the thickness direction, and the first resin member 20 is filled in the through hole 13 and penetrates the through hole 13. Is formed. In this case, the portion of the first resin member 20 filled in the through hole 13 functions as an anchor, and the metal member 10 and the first resin member 20 cannot be separated. Therefore, the structure shown in FIG. 3C is adopted when stronger bonding between the metal member 10 and the first resin member 20 is necessary and it is not necessary to separate them.

  In the example shown in FIG. 3D, the projecting portion 11d is the same as that in FIG. 3C. However, the 1st resin member 20 does not cover the whole overhang | projection part 11d, but covers only the surface by which the 2nd resin member (here not shown) of the metal member 10 is joined, and also the through-hole 13 is covered. It penetrates and is formed so that the front-end | tip part which protruded from the through-hole 13 in the surface on the opposite side of the overhang | projection part 11d becomes larger than the opening size of the through-hole 13. FIG.

  In the configuration shown in FIG. 3D as well, the metal member 10 and the first resin member 20 are normally separated because the portion of the first resin member 20 that penetrates the through hole 13 functions as an anchor, similarly to the configuration shown in FIG. 3C. I can't do it. However, since the first resin member 20 does not cover the entire overhanging portion 11d, the anchor portion of the first resin member 20 can be destroyed by applying an impact force from the outside. The member 10 and the first resin member 20 can be separated.

  In the embodiment described above, a structure in which the metal member 10 and the second resin member 30 are joined via the first resin member 20 so as to form a closed cross section having a metal portion and a resin portion. Body 1 was shown. However, in the present invention, the metal member and the resin member may be joined in any form as long as the metal member and the resin member are joined to form a hollow portion.

  Referring to FIG. 4, the hollow tubular metal member 10 made of metal and the hollow tubular second resin member 30 made of resin are joined in the axial direction via the first resin member 20. The structure 1 is shown. In FIG. 4, the structure 1 is shown in a longitudinal sectional view, not a transverse sectional view.

  The metal member 10 has an overhanging portion 11 formed in a flange shape at its joining end. The first resin member 20 is formed so as to cover the protruding portion 11 over the entire circumference of the metal member 10. Similar to the metal member 10, the second resin member 30 has an overhang portion 31 formed in a flange shape at the joint end portion, and the second resin member 30 is the first resin member 20 in the overhang portion 31. It is joined with.

  The structure 1 shown in FIG. 4 is also produced in the same manner as the structure shown in FIG. That is, the 1st resin member 20 is formed in the overhang | projection part 11 of the metal member 10 by insert molding, and the 1st resin member 20 and the 2nd resin member 30 shape | molded previously are joined by welding after that. Therefore, mutually compatible resins are used for the first resin member 20 and the second resin member 30, and specific examples thereof are as described above. Moreover, also about the form of the junction part of the metal member 10 and the 1st resin member 20, various forms as shown, for example in FIG. 2 and FIG. 3A-3D are possible. However, since the structure 1 shown in FIG. 4 is provided with the first resin member 20 over the entire circumference of the tubular metal member 10, the first resin is required when the metal member 10 and the first resin member 20 need to be separated. Although it is necessary to partially destroy the member 20, for example, the structure shown in FIG.

  The structure of the present invention described above can be applied to various structures in which a metal member and a resin member are joined, and the use thereof is not limited. As an example, automotive parts / units can be preferably cited. Specifically, intake system parts such as intake manifolds, cooling system parts such as radiator pumps, fuel system parts such as fuel pumps, ECU ( There are control system parts such as an engine (Computer Unit) housing, lubricating oil parts such as an oil pump, covers such as a cylinder head cover, and transmission parts.

It is a cross-sectional view of the structure by one Embodiment of this invention. It is a cross-sectional view of the structure by other embodiment of this invention. It is an expansion perspective view which shows an example of the junction part of the edge part of a metal member and the 1st resin member in the structure of this invention. It is an expansion perspective view which shows the other example of the junction part of the edge part of a metal member and the 1st resin member in the structure of this invention. It is the figure which looked at the overhang | projection part shown to FIG. 3B from the side by which the 2nd resin member is joined. It is an expansion perspective view which shows the other example of the junction part of the edge part of a metal member and the 1st resin member in the structure of this invention. It is an expansion perspective view which shows the other example of the junction part of the edge part of a metal member and the 1st resin member in the structure of this invention. It is a longitudinal cross-sectional view of the structure by further another embodiment of this invention which joined the metal member and the resin member to the longitudinal direction.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Structure 10 Metal member 11, 11a, 11b, 11c, 11d Overhang | projection part 12, 13 Through-hole 20 1st resin member 30 2nd resin member 31 Overhang part

Claims (8)

A composite structure having a hollow portion formed by joining a metal member and a resin member,
A metal member having a joining end portion having an overhanging portion projecting toward the outside of the hollow portion ;
A first resin member formed by insert molding on the overhanging portion of the metal member;
A second resin member welded to the first resin member,
The projecting portion has a through-hole penetrating in the thickness direction, and the first resin member is formed through the through-hole,
A composite structure in which the hollow portion is formed by joining the metal member and the second resin member via the first resin member. A composite structure having a hollow portion formed by joining a metal member and a resin member,
A metal member having a joining end portion having an overhanging portion projecting toward the outside of the hollow portion;
A first resin member formed by insert molding on the overhanging portion of the metal member;
A second resin member welded to the first resin member,
The first resin member is formed to cover the overhanging portion,
A composite structure in which the hollow portion is formed by joining the metal member and the second resin member via the first resin member .   The composite structure according to claim 2, wherein the projecting portion has a through hole penetrating in the thickness direction, and the first resin member is formed to penetrate the through hole. The composite structure according to any one of claims 1 to 3 , wherein a closed section is formed by a combination of the metal member, the first resin member, and the second resin member. The composite structure according to any one of claims 1 to 3 , wherein the metal member and the second resin member are tubular members, and ends thereof are joined to each other. A method of manufacturing a composite structure having a hollow portion formed by joining a metal member and a resin member,
Preparing a metal member having a joined end;
Forming a first resin member at a joining end of the metal member by insert molding;
Welding the second resin member formed in a desired shape in advance to the first resin member formed at the joining end, and forming the hollow portion;
The manufacturing method of the composite structure which has this. The method of manufacturing a composite structure according to claim 6 , wherein the step of preparing the metal member includes forming an overhanging portion protruding toward the outside of the hollow portion at the joining end portion. The method of manufacturing a composite structure according to claim 7 , wherein the step of forming the first resin member includes forming the first resin member so as to cover the projecting portion.

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