JP6070013B2 - Metal processing method, metal material, metal resin composite member manufacturing method, and metal material processing apparatus - Google Patents

Description

  The present invention relates to a method for joining a metal material and a resin material.

  Some portable terminals such as notebook personal computers and PDAs use a metal casing (aluminum, magnesium, etc.) for the exterior part from the viewpoints of reduction in thickness and weight and improvement in impact resistance. In the portable terminal, a wireless LAN is the mainstream, and an antenna to be used is built in the liquid crystal side or the main body side of the portable terminal. Furthermore, in recent years, in order to support high-speed wireless LAN, a type in which an antenna is built in the liquid crystal side has become the mainstream.

  Since the metal housing blocks radio waves, in order to incorporate an antenna, at least a portion where the antenna is installed needs to be made of a radio wave permeable substance. Therefore, a method is generally used in which the antenna installation portion is replaced with a resin component and a metal and a resin are joined.

  As a joining method of a metal material and a resin material, a method of adhering with an adhesive or a pressure-sensitive adhesive tape or a method of directly adhering a metal and a resin by increasing adhesion by a metal surface treatment has been used. There was a problem with either method.

  First, there were problems such as the need for purchased materials and low bonding strength. In addition, since the metal surface treatment uses plating treatment, etching treatment, and the like, there are problems such as a large number of treatment steps and a large environmental load due to the use of harmful chemicals.

  A method for solving the above problem is disclosed in Patent Document 1, for example. FIG. 21 is a sectional view showing this method. First, as shown in FIG. 21A, the first inclined hole 102 is formed on the surface of the metal 101 so as to form a predetermined angle with the bonding surface (the surface of the metal 101). For forming the inclined hole, any one of electric discharge machining, drill hole machining, press hole machining, and laser machining is used. Next, by changing the processing angle of the processing apparatus, as shown in FIG. 21B, a second inclined hole 103 having an inclination angle with the joint surface different from that of the first inclined hole 102 is formed. Furthermore, when forming inclined holes with different inclination angles such as the third inclined hole, the fourth inclined hole,..., The processing angle is changed and processed repeatedly. Next, as shown in FIG. 21C, the resin 104 is integrally formed by injection molding, and the joining of the metal and the resin is completed. In addition, if the adhesive is applied to the inclined holes before molding the resin, the bonding strength can be further increased.

  FIG. 22 shows a modification of the method of Patent Document 1. In this example, as shown in FIG. 22A, first, a V-shaped groove 105 is formed at a location where an inclined hole is to be formed. Pressing is used to form the V-shaped groove. Next, a first inclined hole 102 is formed as shown in FIG. By providing the V-shaped groove 105, the drill tip is perpendicular to the metal surface in the case of drilling, so that machining is accurate and the load on the tool is lightened. In the case of laser processing, loss due to oblique incidence of light can be prevented. That is, the power of incident laser light can be fully utilized. Next, by changing the processing angle of the processing apparatus, the second inclined hole 103 is formed as shown in FIG. Furthermore, the method of forming inclined holes with different angles and the method of molding the resin 104 are the same as in the example of FIG.

  According to the above method, since the resin that has entered the inclined holes 102 and 103 acts as a hook, a higher bonding effect can be obtained than when a vertical hole is formed. Further, since the angles of the plurality of inclined holes are different, a strong joint that can withstand external forces from various directions can be obtained.

JP 2009-51131 A

  However, the method of Patent Document 1 has the following problems. In this conventional example, the inclined hole is formed by any one of electric discharge machining, drill hole machining, press hole machining, and laser machining. In these methods, in order to form inclined holes with different inclination angles, a step of adjusting the angle of the processing apparatus for each inclination angle is required. For this reason, there has been a problem that if the variation of the inclination angle is increased, the number of processes is increased in proportion thereto.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for forming inclined holes having different angles without adjusting the angle of the processing apparatus.

  In order to achieve the above object, in the present invention, a step of deforming the one surface into a second surface shape different from the first surface shape by curving a metal material having one surface having a first surface shape; A step of forming a plurality of concave shapes forming a predetermined angle with respect to the average plane of the second surface shape on the one surface, and a third surface different from the second surface shape by curving the metal. A step of deforming into a surface shape.

  The effect of the present invention is that a metal surface having a high anchor effect can be easily obtained.

It is sectional drawing which shows the manufacturing method of 1st Embodiment. It is sectional drawing which shows the example of a process of 1st implementation. It is sectional drawing which shows the formation method of the metal resin joined body by 1st Embodiment. It is sectional drawing which shows another formation method of the metal resin joined body by 1st Embodiment. It is sectional drawing which shows 2nd Embodiment. It is sectional drawing which shows 3rd Embodiment. It is sectional drawing which shows 4th Embodiment. It is sectional drawing which shows 5th Embodiment. It is sectional drawing which shows the manufacturing method of 6th Embodiment. It is sectional drawing which shows the concept of 6th Embodiment. It is sectional drawing which shows 7th Embodiment. It is sectional drawing which shows 8th Embodiment. It is sectional drawing which shows 9th Embodiment. It is sectional drawing which shows 10th Embodiment. It is sectional drawing which shows the example of a process by 10th Embodiment. It is sectional drawing which shows 11th Embodiment. It is a top view which shows the example of a process of 11th Embodiment. It is a perspective view which shows 12th Embodiment. It is a top view which shows the metal material used for 12th Embodiment. It is the top view and sectional drawing of the metal resin joined body used for 12th Embodiment. It is sectional drawing which shows the prior art. It is sectional drawing which shows the modification of a prior art.

Next, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
1A to 1F show a method for processing a metal material joint surface in the present embodiment.

  In this embodiment, a press device is used. As shown in FIG. 1, the pressing device has a pressing die 1, a stationary die 2, and a receiving die 3 that can move independently of each other. The pressing die 1 has a curved surface facing the receiving die 3, and a plurality of fine convex shapes 4 are formed on the surface. The fixed mold 2 is arranged around the pressing mold 1, and the surface facing the receiving mold 3 is a curved surface that is an extension of the curved surface of the pressing mold 1. The opposing surface of the receiving die 3 is a curved surface having a size obtained by adding the thickness of the metal material 5 to the pressing die 1 and the stationary die 2.

  FIG. 1 illustrates the case where the metal material 4 is a flat plate. However, when the metal material 4 is sandwiched between the pressing die 1 and the fixed die 2 and the receiving die 3, a shape that can follow the curved surface formed by these. And any material can be used in the same manner.

  Next, a processing method will be described. First, as shown in FIG. 1A, the metal material 4 is disposed between the pressing die 1 and the fixed die 2 and the receiving die 3.

  Next, as shown in FIG. 1B, the fixed mold 2 is moved, and the metal material 4 is sandwiched between the lower surface of the fixed mold 2 and the upper surface of the receiving mold 3. At this time, the metal material 5 is held so as to follow the curved surface of the receiving mold 3. In addition, it is desirable that there is an extra length protruding around the fixed mold 2 and the receiving mold 3 in order to restore elasticity after processing.

  Next, as shown in FIG. 1C, the pressing die 1 is moved and pressed with the receiving die 3. The fine convex shape 4 provided on the pressing die 1 is pushed into the metal material 5 by pressing. By this plastic working, a concave shape 6 having a side wall parallel to the moving direction of the pressing die 1 is formed on the surface of the metal material 5.

  Next, as shown in FIG. 1D, the pressing die 1 is released in a state where the periphery of the metal material 5 is fixed by the fixed die 2 and the receiving die 3.

  Next, the fixed mold 2 is released as shown in FIG. When the mold is released, the metal material 5 returns to the original flat plate shape by elastic restoration.

  Finally, the processed metal material 5 is taken out from the press device, and the processing is completed as shown in FIG.

  Next, the concave shape 6 formed by the present embodiment will be described in detail using specific examples. FIG. 2 shows a state in which a concave shape is formed in a state where the metal material 5 is curved (a), a state in which the concave shape is returned to a flat plate by elastic restoration (b), and an enlarged portion of the concave shape 6 at this time (c) ) Is schematically shown. In this embodiment, the length of the metal material 5 is 50 mm, and the radius of curvature of the receiving mold 3 is 50 mm. The angle is defined with the bottom of the curved surface being 0 degrees. Here, attention is paid to the concave shape 6a located at the 0 degree point, the concave shape 6b located at the 15 degree point, and 6c located at the 30 degree point.

  In the state of FIG. 2A in which the metal material 5 is bent, each concave shape 6 has a shape extending in the direction of 0 degree. In the state of FIG. 2B restored to a flat plate shape, the metal material 5 has an angle with respect to the surface. The angle described here is an angle formed by a line segment connecting the center of the opening of the recess 6 and the bottom of the recess and a normal line standing on the surface of the metal material 5.

  FIG. 2C is an enlarged view of the three concave shapes 6 extracted from FIGS. 2A and 2B. As is apparent from FIG. 2 (c), 6a is 0 degrees, 6b is 15 degrees, and 6c is 30 degrees, each of which has a concave shape 6 whose center line has an angle with respect to the surface of the metal material 5. For this reason, when it joins with resin, a higher anchor effect is acquired, so that it goes to an end. In the above description, a relatively large angle of 15 degrees or 30 degrees has been described. However, if there is an inclination angle, an anchor effect corresponding to the inclination angle is generated, so the size of the angle is not limited.

  FIG. 3 shows a method of joining a resin to the metal material 5 processed as in the above embodiment. First, as shown in FIG. 3A, the metal material 5 is set in the injection mold 7. Next, as shown in FIG. 3 (b), the cylinder 8 is attached to the mold and the molten resin 9 is poured into the mold. Next, after cooling and solidifying the resin 9, it is taken out to complete the metal resin bonded body 10 as shown in FIG. As described with reference to FIG. 2, the metal resin bonded body 10 formed in this way has a higher anchor effect as it is closer to the end. That is, since the bonding strength at the end is high, the effect that the metal material 5 and the resin 9 are difficult to peel off can be obtained.

  An adhesive 11 may be used to join the resin 9. FIG. 4 is a sectional view showing such an example. First, as shown in FIG. 4A, a metal material 5 having a recess 6 according to the present invention is prepared. Next, the adhesive 11 is applied as shown in FIG. Next, a plate-like resin 9 is bonded as shown in FIG. Even when the adhesive 11 is used, since the adhesive strength between the adhesive 11 and the metal material 5 is increased by the anchor effect, the resin 9 and the metal material 5 can be firmly bonded.

As described above, according to the present embodiment, since concave shapes having different angles can be formed, a metal material that produces a high anchor effect can be obtained. Moreover, using this, the resin 9 and the metal material 5 can be firmly bonded. Furthermore, since it can process without adjusting the angle of a processing apparatus, processing time can be reduced significantly compared with the conventional processing method.
(Second Embodiment)
FIG. 5 is a sectional view showing a second embodiment of the present invention. In the present embodiment, the concave shape 6 is formed by sculpting electric discharge machining using the electric discharge machining electrode 12. Other steps are the same as those in the first embodiment. The concave shape 6 can be formed by using a drill or other cutting.
(Third embodiment)
FIG. 6 is a cross-sectional view showing a third embodiment of the present invention. In the present embodiment, the concave shape 6 is formed using the laser light 14 emitted from the laser 13. Other steps are the same as those in the first embodiment.
(Fourth embodiment)
7A and 7B are schematic views showing the fourth embodiment, where FIG. 7A is a plan view and FIG. 7B is a cross-sectional view. In the present embodiment, the concave shape 6 is formed in a stripe. The center line of the concave shape 6 at this time is formed so that the angle becomes larger as it is closer to the end as in the first to third embodiments. Since the processing of the present embodiment can be performed using a dicer or a milling machine that operates at high speed, it is suitable for processing a large-area metal material 5 that is difficult to handle with a mold.
(Fifth embodiment)
In the present embodiment, the processing method is used when the shape of the metal material 5 is not restored to the original flat plate shape after releasing the holding of the fixed die 2 and the receiving die 3. FIG. 8 is a cross-sectional view showing a fifth embodiment of the present invention. First, as shown in FIG. 8A, the concave shape 6 is formed by the processing methods of the first to fourth embodiments. Next, the holding of the metal material 5 by the fixed mold 2 and the receiving mold 3 is released, and the metal material 5 is taken out. At this time, the metal material 5 is in a state in which the deformation made during processing does not completely return. Next, as shown in FIG. 8B, it is set in a press machine provided with a flat plate pressing die 15 and a flat plate receiving die 16. Next, as shown in FIG. 8C, the metal material 5 is pressed by the flat plate pressing die 15 and the flat plate receiving die 16. Next, the metal material 5 is taken out from the press machine, and the flat metal material 5 is completed as shown in FIG.
(Sixth embodiment)
FIG. 9 is a cross-sectional view showing the present embodiment. In the present embodiment, the metal material 5 is curved into a convex surface shape to form the concave shape 6. The processing procedure is the same as in the first embodiment except that the surface shapes of the pressing die 1, the stationary die 2, and the receiving die 3 are convex upward.

Protruding upward has an advantage not found in the case of convex downward. FIG. 10 is a schematic cross-sectional view showing the concept. FIG. 10A shows a state in which the concave shape 6 is formed with the metal material 5 convex upward. Here, the side wall 17 of the concave shape 6 is formed with an inclination of θ with respect to the normal of the surface of the metal material 5. FIG.10 (b) has shown the state which returned the metal material 5 to the flat plate shape. As shown in FIG. 10B, at this time, the diameter of the concave shape 6 becomes smaller as it is closer to the opening, and the side wall 17 is inclined inward by θ. That is, the side wall 17 forms an overhang shape. An anchor effect is further heightened by becoming overhang shape. In addition, although the dimension is drawn wide for description, application of this invention is not restricted to this dimension.
(Seventh embodiment)
In this embodiment, after forming the concave shape 6 in the metal material 5, it is deformed into a surface shape other than the flat plate shape and joined to the resin 9. FIG. 11 is a sectional view showing this technique.

First, as shown in FIG. 11A, the concave shape 6 is formed by making the metal material 5 into a convex curved surface. Next, as shown in FIG. 11B, after the metal material 5 is deformed upwardly into a convex curved surface, the resin 9 is integrally formed. In the case of this component, the closer the end of the component to which the peeling force is likely to be applied, the higher the bonding strength, and thus the overall strength is increased.
(Eighth embodiment)
In the present embodiment, the surface shape of the metal material 5 when forming the concave shape 6 is not a single convex curved surface or a concave curved surface, but is curved in a complicated manner. An example is shown in FIG. 12A shows a state in which the concave shape 6 is formed in the metal material 5, and FIG. 12B shows a state in which the resin 9 is integrally formed by deforming it into a different surface shape. It is also possible to further increase the bonding strength by adjusting the angle at which the concave shape 6 is formed according to the shape of the part in which the metal and the resin are bonded.
(Ninth embodiment)
FIG. 13 is a perspective view showing an example of the ninth embodiment. In the present embodiment, the deformation of the metal material 5 and the formation of the concave shape 6 are performed a plurality of times. First, a flat metal 5 as shown in FIG. Next, as shown in FIG. 13B, the metal material 5 is deformed into a convex cylindrical surface. Although the deformation means is not shown, a set of a fixed die 2 and a receiving die 3 is used, for example, as in the other embodiments. Next, a plurality of concave shapes 6u are formed in the concave shape forming direction 18 as shown in FIG. Next, as shown in FIG. 13 (d), the metal material 5 is deformed and fixed to a cylindrical surface convex downward. Next, as shown in FIG. 13 (e), the recess 6 v is formed in the recess forming direction 18. Next, it returns to the original flat plate shape as shown in FIG. Moreover, although the central axis direction of the cylindrical surface of FIG.13 (b) and FIG.13 (d) showed the same example, it is not restricted to this, For example, it deform | transforms into different directions, such as a direction where a central axis mutually orthogonally crosses. May be. Furthermore, although the example which deform | transforms into a cylindrical surface was shown here, it is not restricted to this. Other curved surfaces such as a spherical surface and a bowl-shaped curved surface may be used.

By doing as described above, the concave shape 6 having various inclinations can be formed, so that the anchor effect can be further enhanced. Also, by applying this embodiment, it is possible to control the strength distribution of the anchor effect according to the finished shape.
(Tenth embodiment)
FIG. 14 is a cross-sectional view showing a ninth embodiment of the present invention. In the present embodiment, the receiving mold 3 curved to various curvatures is used. The pressing die 1 is formed smaller than the area of the material. The pressing die 1 is held by a movable arm 19. Although not shown, the metal material 5 is also held so as to be movable with respect to the receiving mold 3. That is, the pressing die 1 and the metal material 5 can move independently of the receiving die 3.

When such an apparatus is used, a desired portion of the metal material 5 can be positioned at a position having a desired curvature in the receiving die 3, and a concave shape can be formed by the pressing die 1. That is, the concave shape 6 having a desired inclination angle can be formed at a desired position of the metal material 5. FIG. 15 shows a processing example.
(Eleventh embodiment)
The eleventh embodiment is an example of processing using a device in which the pressing die 1 is divided into two parts, the pressing die 1a and the pressing die 1b, and can be pressed independently. FIG. 16 shows an outline of the apparatus. The receiving die 3 is formed in a downwardly convex curved surface, and the pressing die 1 and the fixed die 2 are formed in a curved surface following the curved surface. The stamping die 1 is divided into two parts, each of which can move independently. The receiving mold 3 is provided so as to be rotatable in the horizontal direction.

FIG. 17 shows a processing example using this apparatus. The procedure for processing this metal material 5 is as follows. First, the pressing die 1a and the pressing die 1b are pressed at the same time to process the regions a20a and b20b in which the concave shapes are formed. Next, the receiving die 3 is rotated 90 degrees, and the concave shape 6 is formed in the region c20c using only the pressing die 1b. As described above, the concave shape 6 can be formed in two directions. Further, if the metal material 5 can be moved with respect to the pressing die 1 here, the concave shape 6 can be formed also in the blank area in FIG. By using the apparatus of the present embodiment, the concave shape 6 can be efficiently formed in the large-area metal 5.
(Twelfth embodiment)
FIG. 18 is a perspective view showing a notebook personal computer 21 manufactured using the technique of the present embodiment. In recent years, it has become common for the notebook computer 21 to have a wireless function. In order to realize this function, there is a technique in which an antenna is built in, the antenna installation part 22 cuts out the metal of the casing, and a radio wave permeable resin is integrally joined thereto. 18 to 20 show the technique.

FIG. 19 shows an example of processing the metal material 5 used for the top plate of the notebook computer 21. The periphery of the notch corresponding to the antenna installation portion 22 is staggered by the thickness for which the resin is provided to form the concave shape forming region 23 in which the concave shape 6 of the present invention is formed on the bottom surface. Next, a resin 9 is integrally formed so as to be flush with the metal material 5 as shown in FIG. FIG. 20B is a cross section taken along the line AA ′ of FIG. By forming in this way, a top plate for the notebook computer 21 in which the metal and the resin are firmly bonded can be created. In this embodiment, an example of a notebook computer is shown. It can also be applied to various home appliances such as TVs and refrigerators, furniture, appliances, tools and parts.
(Appendix 1)
A first step of deforming the metal surface into a first surface shape, a second step of forming a recess in the same direction on the surface of the metal, and the metal surface different from the first surface shape. The metal processing method characterized by including the 3rd process deform | transformed into a 2nd surface shape in order.
(Appendix 2)
After the third step, a fourth step of forming a plurality of recesses in the same direction on the surface of the metal, and deforming the metal surface into a third surface shape different from the first surface shape The metal processing method according to appendix 1, further comprising: a fifth step.
(Appendix 3)
The metal processing method according to claim 1, wherein the first surface shape is a surface shape that is convex upward when viewed from the formation surface of the recess.
(Appendix 4)
The surface shape deformed after the formation of the concave portion is a surface shape that is convex below the surface shape before the formation of the concave portion when viewed from the formation surface of the concave portion, so that the side wall of the concave portion has an overhang shape. The metal processing method according to 1 or 2
(Appendix 5)
The metal processing method according to any one of appendices 1 to 4, wherein the first step is performed within elastic deformation of the metal.
(Appendix 6)
The metal processing method according to any one of appendix 1 to appendix 5, wherein the second step is press machining, electric discharge machining, or laser machining.
(Appendix 7)
A metal material processed by the metal processing method according to any one of appendices 1 to 6, wherein a plurality of recesses having different inclinations are provided on the surface of the metal.
(Appendix 8)
A method for producing a metal-resin composite member comprising a step of adhering a resin to the formation surface of the recess after finishing the deformation of the metal by the metal processing method according to appendices 1-6.
(Appendix 9)
A step of providing a plurality of recesses in the same direction on the surface of the metal, a step of deforming the metal such that the plurality of recesses are directed in two or more different directions, and the metal having the recesses formed therein. A method for producing a metal-resin composite member, comprising a step of integrally molding a resin in contact with a surface.
(Appendix 10)
The method for producing a metal-resin composite member according to appendix 9, wherein the step of integrally molding the resin is injection molding.
(Appendix 11)
The method for producing a metal-resin composite member according to appendix 9 or appendix 10, wherein the step of deforming the metal continuously changes an inclination of the plurality of adjacent concave portions with respect to the metal surface.
(Appendix 12)
A metal processing apparatus comprising: a fixing unit that deforms and holds a surface shape of a metal surface; and a recess forming unit that forms a plurality of recesses in the same direction on the metal surface.
(Appendix 13)
The metal processing apparatus according to appendix 12, wherein the fixing means is a receiving mold and a fixed mold that form a pair with a single curved surface interposed therebetween.

DESCRIPTION OF SYMBOLS 1 Push type 2 Fixed type 3 Receiving type 4 Convex shape 5 Metal material 6 Concave shape 7 Molding die 8 Cylinder 9 Resin 10 Metal resin joined body 11 Adhesive 12 Electric discharge machining electrode 13 Laser 14 Laser beam 15 Flat plate die 16 Flat plate receiver Mold 17 Side wall 18 Concave shape forming direction 19 Movable arm 20a Region a
20b region b
20c region c
21 Notebook PC 22 Antenna Installation Section 23 Concave Shape Formation Area 101 Metal 102 First Inclined Hole 103 Second Inclined Hole 104 Resin 105 V-shaped Groove

Claims (10)

A first step of deforming the metal surface into a first surface shape;
A second step of forming a plurality of recesses in the same direction on the surface of the metal;
A third step of deforming the metal surface into a second surface shape different from the first surface shape ;
After the third step, a fourth step of forming a plurality of recesses in the same direction on the surface of the metal;
A metal processing method comprising: a fifth step of deforming the metal surface into a third surface shape different from the first and second surface shapes . The metal processing method according to claim 1, wherein the first surface shape is a surface shape that is convex upward when viewed from a surface on which the concave portion is formed.   A first step of deforming the metal surface into a first surface shape;
  A second step of forming a plurality of recesses in the same direction on the surface of the metal;
  A third step of deforming the metal surface into a second surface shape different from the first surface shape;
  By making the surface shape deformed after the formation of the concave portion into a convex shape lower than the surface shape before the formation of the concave portion when viewed from the formation surface of the concave portion, the side wall of the concave portion is formed into an overhang shape.
  The metal processing method characterized by the above-mentioned.   The metal processing method according to claim 3, wherein the first surface shape is a surface shape that is convex upward as viewed from the formation surface of the recess.   A first step of deforming the metal surface into a first surface shape;
  A second step of forming a plurality of recesses in the same direction on the surface of the metal;
  A third step of deforming the metal surface into a second surface shape different from the first surface shape;
The first step is performed within the elastic deformation of the metal
  The metal processing method characterized by the above-mentioned. The metal processing method according to claim 5, wherein the first surface shape is a surface shape that is convex upward when viewed from the formation surface of the recess.   A first step of deforming the metal surface into a first surface shape;
  A second step of forming a plurality of recesses in the same direction on the surface of the metal;
  A third step of deforming the metal surface including the region where the plurality of recesses are formed into a second surface shape different from the first surface shape;
The metal processing method characterized by including. A metal resin comprising a step of adhering a resin to a formation surface of the recess after finishing the deformation of the metal by the metal processing method according to claim 1. A method for producing a composite member.   A step of providing a plurality of recesses in the same direction on the surface of the metal, a step of deforming the metal such that the plurality of recesses are directed in two or more different directions, and the metal having the recesses formed therein. A method for producing a metal-resin composite member, comprising a step of integrally molding a resin in contact with a surface.   An apparatus for processing a metal material, comprising: means for deforming and fixing a surface shape of a metal surface; and means for forming a plurality of recesses in the same direction on the surface of the metal.

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