JP7284406B2 - Manufacturing method of joint structure of metal member and resin member - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a joint structure of a metal member and a resin member, and more particularly to a method for mechanically joining a metal member and a resin member by an anchor effect.

In recent years, in the fields of automobiles, aircraft, railroad vehicles, electrical equipment, etc., the development of technology for directly joining metal members and resin members has been progressing in order to achieve required mechanical properties while reducing weight. As such a technique, there is a manufacturing method of mechanically joining a metal member and a resin member by an anchor effect (for example, see Patent Documents 1 to 3).

In Patent Document 1, a processing laser L1 (FIG. 3 of Patent Document 1) is used. A perforated portion 11 is formed in the metal member 1 by the laser L1, and a projecting portion 11a projecting inward is formed in the perforated portion 11. As shown in FIG. By filling the perforated portion 11 with a resin member and solidifying the resin member, the metal member 1 and the resin member 2 are mechanically joined by an anchor effect (Fig. 1 of Patent Document 1).

In Patent Document 2, a mold 8 (Figs. 3 and 4 of Patent Document 2) and a metal plate 9 (Figs. 6 and 7 of Patent Document 2) are used. While compressing the metal base material 11 using the mold 8, by ultrasonically vibrating the mold 8 in the direction along the molding surface 11b of the metal base material 11, the protrusion surface metal base material 12 having the protrusions 12a to form Next, the metal plate 9 is used to compress the projection surface metal base material 12 to form the metal member 1 having the undercut portion 1b. Next, by filling the undercut portion 1b of the metal member 1 with a resin material and solidifying it, the metal member 1 and the resin member 2 are mechanically joined by an anchor effect (Fig. 1 of Patent Document 2).

In Patent Document 3, a pressing member 16 (FIGS. 1 and 4 of Patent Document 3) is used. The resin member 12 and the metal member 11 having the grooves 15 formed in the joint surface 11a with the resin member 12 are superimposed, and heat and pressure are applied from the metal member 11 side by the pressing member 16 . As a result, the resin member 12 is softened and put into the groove portion 15, and by solidifying the resin that has entered the groove portion 15, the metal member 11 and the resin member 12 are mechanically joined by an anchor effect (Patent Document 3). 4).

JP 2016-141052 A JP 2017-039274 A JP 2015-189172 A

In the method of manufacturing a bonded structure of a metal member and a resin member in Patent Documents 1 to 3, the undercut shape of the metal member in a plurality of manufactured bonded structures does not become the same. Bonding strength becomes unstable.

For example, in Patent Literature 1, the perforated portion 11 is formed by removal processing using a laser L1. That is, the perforated portion 11 is formed by focusing the laser beam L1 on the surface of the metal member 1 to melt it, and blowing off the assist gas by spraying it. Therefore, since the shape of the formed perforated portion 11 is not the same among the plurality of manufactured metal members 1, the bonding strength between the metal member 1 and the resin member 2 becomes unstable.

Moreover, in Patent Document 2, the shape of the undercut portion 1b formed in the metal member 1 by the pressing and ultrasonic vibration of the mold 8 and the pressing of the metal plate 9 does not become the same in the plurality of manufactured metal members 1. , the bonding strength between the metal member 1 and the resin member 2 becomes unstable.

Furthermore, in Patent Document 3, the undercut-shaped groove 15 of the metal member 11 deformed by applying heat and pressure by the pressing member 16 is not the same in the plurality of manufactured metal members 11, and the groove is softened and softened. Since the amount of resin entering 15 also fluctuates, the bonding strength between metal member 11 and resin member 12 becomes unstable. For example, in some cases, the resin that enters the groove 15 of the metal member 11 barely enters the groove 15, in which case the bonding strength between the metal member 11 and the resin member 12 is greatly reduced.

Furthermore, the method of manufacturing a joined structure of a metal member and a resin member in Patent Documents 1 and 2 requires large-scale equipment. That is, Patent Document 1 requires a laser processing machine, and Patent Document 2 requires a large press machine and a device for ultrasonically vibrating a mold.

In addition, in the method of manufacturing a bonded structure of a metal member and a resin member disclosed in Patent Document 3, it takes time to apply heat and pressure from the metal member 11 side by the pressing member 16 to soften the resin member 12. diminished sexuality. In addition, traces of the pressing member 16 remain on the metal member 11 .

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a joint structure between a metal member and a resin member that can stabilize the joint strength between the metal member and the resin member.

In order to solve the above problems, the method for manufacturing a joint structure of a metal member and a resin member according to the present invention includes:
On the surface of a flat metal member,
a concave portion consisting of a plurality of vertical holes, or
a concave portion consisting of a plurality of vertical grooves, or
a recessed portion forming step of forming a recessed portion composed of a plurality of vertical holes and vertical grooves by mechanical removal processing;
The flat metal member that has undergone the concave portion forming step,
All or part of the plurality of holes, or the plurality of grooves, or the plurality of holes and the grooves, which are the concave portions, are bent in the out-of-plane direction so as to form an undercut shape as a whole. A bending step of bending and deforming the metal member into a metal member after bending deformation;
Using a mold having a cavity on the surface side of the metal member after the bending deformation that has undergone the bending step, where the concave portion is formed, a molten or plasticized resin material is introduced into the cavity from the gate of the mold. an injection molding step of molding a resin member into the shape of the cavity by injecting it into the cavity;
characterized by comprising

According to such a manufacturing method, since the concave portions formed of holes and/or grooves perpendicular to the surface of the flat metal member are formed by mechanical removal processing in the concave portion forming step, the flat metal member can be The shape accuracy of the formed concave portion is improved. That is, when the concave portions are formed on a plurality of flat metal members, the concave portions have substantially the same shape in any of the flat metal members.

Further, the shape of the concave portion formed in the flat metal member in the concave portion forming step is substantially the same in the plurality of metal members after bending deformation even when the metal member is bent in the bending step.

Then, when molding the resin member in the cavity of the mold in the injection molding process, the molten or plasticized resin is placed in the concave portion where the shape of the plurality of metal members after bending deformation is substantially the same as described above. The material is reliably filled with the required filling pressure.

Therefore, in the manufactured bonded structure of a plurality of metal members and a resin member, the plurality of holes, the plurality of grooves, or all or part of the plurality of holes and the grooves are under the joint structure as a whole. The shape of the recess, which is the cut shape, and the amount of resin filled in the recess are substantially the same. As a result, in a joint structure in which the metal member and the resin member are mechanically joined by an anchor effect, the joint strength between the metal member and the resin member is stabilized.

Therefore, the bonding strength between the metal member and the resin member can be guaranteed by controlling the materials of the metal member and the resin member and the shape of the concave portion. Moreover, since the molten or plasticized resin flows into the concave portion without gaps and fills the concave portion without any gaps, it is possible to provide a joint structure in which the metal member and the resin member are fixed with resin breaking strength.

Furthermore, in the step of forming the concave portions, the holes and grooves are formed perpendicular to the surface of the flat metal member, so the processing equipment for forming the holes and grooves on the surface of the metal member does not become large-scale, and the processing time is reduced. Since it can be shortened, the manufacturing cost can be reduced.

Here, in a preferred embodiment, the bending step is performed by sheet metal press working.

According to such a manufacturing method, since the bending of the flat metal member is performed by sheet metal press working, the bending is efficiently performed using a die, so that the productivity can be improved.

According to the manufacturing method of the joint structure of the metal member and the resin member as described above, the joint strength between the metal member and the resin member can be stabilized. Accordingly, the bonding strength can be guaranteed by controlling the materials of the metal member and the resin member and the shape of the concave portion formed in the metal member.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing an example of a joined structure manufactured by a method of manufacturing a joined structure of a metal member and a resin member according to an embodiment of the present invention; It is a longitudinal cross-sectional view showing an example of the joint structure. FIG. 10 is a perspective view showing an example of the flat metal member after forming recesses in the flat metal member in a recess formation step; It is a longitudinal cross-sectional view showing an example of the metal member. FIG. 4 is a perspective view showing an example of a metal member after bending deformation in which a flat metal member is bent in an out-of-plane direction in a bending process. It is a longitudinal cross-sectional view showing an example of the metal member. It is a schematic longitudinal section showing an example of an injection molding process. FIG. 11 is a perspective view showing a modified example of a recessed portion formed in a recessed portion forming step; 5B is a cross-sectional view corresponding to arrow X1-X1 in FIG. 5A showing the metal member after bending deformation in the out-of-plane direction of the metal member in FIG. 5A in a bending process. FIG. 5B is a cross-sectional view corresponding to the arrow X2-X2 in FIG. 5A showing the metal member after bending deformation in the out-of-plane direction of the metal member in FIG. 5A in a bending process. FIG. FIG. 11 is a perspective view showing another modified example of the concave portion formed in the concave portion forming step; 6B is a cross-sectional view corresponding to the arrow X3-X3 of FIG. 6A, showing a modification of bending in the bending process. FIG. A bonded structure manufactured by the method for manufacturing a bonded structure of a metal member and a resin member according to the embodiment of the present invention when the direction of bending deformation of the flat metal member in the out-of-plane direction is changed in the bending process. It is a perspective view showing an example of. It is a longitudinal cross-sectional view showing an example of the joint structure.

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment according to the present invention will be described below with reference to the drawings.

<Junction structure between metal member and resin member>
As shown in the perspective view of FIG. 1A and the vertical cross-sectional view of FIG. 1B, a joined structure 1 manufactured by the method for producing a joined structure of a metal member and a resin member according to the embodiment of the present invention includes a metal member and a resin member. 2 and a resin member 3.

The metal member 2 is, for example, an iron alloy, a copper alloy, or the like, or a light alloy such as aluminum, magnesium, titanium, or beryllium.

The resin member 3 is, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyamide (PA), polyacetal (POM), polybutylene terephthalate (PBT), engineering plastics such as polycarbonate (PC), polypropylene (PP ), general-purpose plastics such as polystyrene (PS), polymethyl methacrylate (PMMA), polyethylene (PE) or ABS resin (ABS), or thermosetting resins such as phenolic resin (PF) or epoxy resin (EP) be. Further, a fibrous reinforcing material such as glass fiber or carbon fiber may be added to the resin member 3 .

The metal member 2 is, for example, a plate having an arc-shaped cross section as shown in FIG. A group of holes H formed by .

Since the central axes F1 to F5 of the holes 4A to 4E forming the concave portion A are perpendicular to the outer peripheral surface E of the metal member 2, which is a plate having an arc-shaped cross section, the holes 4A to 4E (hole group H The recess A) has an undercut shape as a whole. Here, the "undercut shape" refers to a shape in which the metal member 2 and the resin member 3 cannot be separated from each other when the resin member 3 enters the concave portion A as shown in FIG. 1B.

Since the concave portion A has an undercut shape, the metal member 2 and the resin member 3 are mechanically and firmly joined by an anchor effect.

<Manufacturing method of joined structure of metal member and resin member>

(Concave portion forming step)
As shown in the perspective view of FIG. 2A and the vertical cross-sectional view of FIG. 2B, a concave portion forming step is performed to form concave portions A on the surface E of a rectangular flat metal member 2A by mechanical removal processing. That is, 15 holes 4A to 4E perpendicular to the planar surface E, which are three on each of the five rows R1 to R5, are cut by applying rotation and feed to the drill using, for example, a drilling machine or a machining center. do.

The arrangement of the plurality of holes formed in the surface E of the rectangular plate-like metal member 2A is not limited to the vertical and horizontal arrangement as shown in FIG. . The number and arrangement of holes in the hole group H, which is the concave portion A, and the diameter and depth of each hole are appropriately selected based on the required specifications and the like.

(bending process)
Next, the rectangular plate-shaped metal member 2A that has undergone the concave portion forming step shown in FIGS. 2A and 2B is bent in the out-of-plane direction B so that all or part of the concave portion A becomes an undercut shape. Then, a bending process is performed to form the metal member 2B after bending deformation. That is, for example, bending is performed by sheet metal press working to obtain a metal member 2B after bending deformation that has an arc shape as shown in the perspective view of FIG. 3A and the vertical cross-sectional view of FIG. 3B.

By bending the metal member 2A in the form of a rectangular flat plate by sheet metal press working, it is possible to efficiently bend the metal member 2A using a mold, so that productivity can be improved.

(Injection molding process)
Next, as shown in the schematic longitudinal section of FIG. 4, the metal member 2B after bending deformation through the bending process shown in FIGS. Using a mold D having a cavity C on the side of the surface E on which the part A is formed, after the mold is clamped, a molten or plasticized resin material P is introduced into the cavity C from the gate G of the mold D. An injection molding process is performed to mold the resin member 3 into the shape of the cavity C by injecting. By changing the shape of the cavity C of the mold D, the resin member 3 having an arbitrary three-dimensional shape can be molded.

(Cooling/solidification process)
After performing the injection molding process, a cooling/solidifying process is performed in which the melted or plasticized resin material P is cooled while applying pressure.

(Molded article extraction process)
After the cooling and solidification process is performed, a molded article extraction process is performed in which the injection molding die is opened and the bonded structure 1 (FIGS. 1A and 1B), which is a molded article, is extracted from the die D. FIG. In addition, gate cut is performed as needed.

<Modified example of concave portion>
Holes 4F to 4H and grooves 5A to 5E are formed on the surface E of the rectangular flat metal member 2A shown in the perspective view of FIG. That is, the concave portion A is composed of a hole group H of holes 4F to 4H and a groove group S of grooves 5A to 5E.

In the concave portion forming step of forming the hole group H and the groove group S, which are the concave portion A, in the rectangular flat metal member 2A of FIG. The groove group S is cut by rotating and moving an end mill using, for example, a general-purpose milling machine or a machining center.

The arrangement of the plurality of holes and grooves formed on the surface E of the rectangular flat metal member 2A is not limited to the arrangement shown in FIG. 5A. The number and arrangement of holes in the hole group H, which is the concave portion A, the diameter and depth of each hole, the number and arrangement of the grooves in the groove group S, and the width, length and depth of each groove are determined according to requirements. Select as appropriate based on specifications.

As shown in FIG. 5B, which is a cross-sectional view corresponding to the arrow X1-X1 in FIG. 5A, and FIG. 5C, which is a cross-sectional view corresponding to the arrow X2-X2 in FIG. 5A, the rectangular flat metal member 2A in FIG. When a bending process is performed on the metal member 2B after bending deformation, all or part of the recessed portions A (the hole group H and the groove group S) become an undercut shape.

2 A of flat metal members are not limited to a rectangle. The flat metal member 2A may have any shape such as a circle, an ellipse, an ellipse, and a square with rounded corners. It suffices if a part can be made into an undercut shape.

Alternatively, the recessed portion A may be composed of the groove group S only. In other words, the concave portion A formed on the surface of the flat metal member 2A in the concave portion forming process may consist of a plurality of vertical grooves.

Therefore, the concave portion A formed on the surface of the flat metal member 2A in the concave portion forming step is
(1) When it consists of a plurality of vertical holes, for example, as shown in FIG. 2A,
(2) when it consists of a plurality of vertical grooves,
(3) When it consists of a plurality of vertical holes and vertical grooves, for example, as shown in FIG. 5A,
There is

<Another Modified Example of the Concave Portion and a Modified Example of the Bending Process>
In the surface E of the rectangular flat metal member 2A shown in the perspective view of FIG. 4I to 4N are formed. That is, the nine holes 4I to 4K are formed in rows R1 to R3 near one of the short sides of the rectangular flat metal member 2A, and the rows near the other short side are formed. Nine holes 4L-4N on R4-R6 are formed.

As shown in FIG. 6B, which is a cross-sectional view corresponding to the arrow X3-X3 in FIG. 6A, the metal member 2B after bending deformation in which the bending process is performed is shown in FIGS. 3A and 3B, and FIGS. 5B and 5C. It has a dished cross-section rather than an arcuate cross-section. That is, in the metal member 2B after bending deformation, the portion including the rows R1 to R3 and the portion including the rows R4 to R6 in FIG. shape.

Holes 4I to 4N, which are concave portions A (hole group H) in metal member 2B after bending deformation, form an undercut shape as a whole. Therefore, in the joint structure 1 formed by joining the metal member 2 and the resin member 3 through an injection molding process or the like as shown in FIG. 6B, the metal member 2 and the resin member 3 are mechanically firmly joined by the anchor effect.

The metal member 2 (the metal member 2B after bending deformation) of the joined structure 1 shown in the perspective view of FIG. 7A and the vertical cross-sectional view of FIG. 7B is the joint shown in the perspective view of FIG. The metal member 2 (metal member 2B after bending deformation) of the structure 1 and the rectangular plate-shaped metal member 2A shown in the perspective view of FIG. 2A and the vertical cross-sectional view of FIG. The direction of bending deformation is different. That is, in FIGS. 1A and 1B, the concave portion A is formed on the outer peripheral surface E of the metal member 2, and in FIGS. 7A and 7B, the concave portion A is formed on the inner peripheral surface E of the metal member 2. .

7A and 7B, the central axes F1 to F5 of the holes 4A to 4E forming the recess A are perpendicular to the inner peripheral surface E of the metal member 2, which is a plate having an arc-shaped cross section. Therefore, the holes 4A to 4E (the concave portion A that is the hole group H) as a whole form an undercut shape. Therefore, the metal member 2 and the resin member 3 are mechanically and firmly joined by the anchor effect.

1B, 3B, 5B, 5C, and 7B, or It is not limited to the dish-shaped cross section as shown in FIG. 6B, and any shape that bends and deforms the flat metal member 2A so that the concave portion A in the metal member 2B after bending deformation forms an undercut shape as a whole. Just do it.

<Effect>
According to the manufacturing method of the joint structure 1 of the metal member 2 and the resin member 3 according to the embodiment of the present invention, the holes and/or grooves perpendicular to the surface E of the flat metal member 2A are formed in the concave portion forming step. Since the concave portion A is formed by mechanical removal processing, the shape accuracy of the concave portion A formed in the flat metal member 2A is increased. That is, when the concave portions A are formed in a plurality of flat metal members 2A, the concave portions A have substantially the same shape in any of the flat metal members 2A.

Further, the shape of the concave portion A formed in the flat metal member 2A in the concave portion forming step is substantially the same in the metal member 2B after a plurality of bending deformations even if the metal member 2A is bent in the bending step. Become.

Then, when molding the resin member 3 in the cavity C of the mold D in the injection molding process, the molten resin is injected into the concave portion A where the shape of the metal member 2B after bending deformation is substantially the same as described above. Alternatively, the plasticized resin material P is reliably filled at a required filling pressure.

Therefore, in the manufactured joint structure 1 of the plurality of metal members 2 and the resin member 3, the shape of the concave portion A, which is wholly or partially undercut, and the amount of resin filled in the concave portion A are become approximately the same. Thereby, in the joint structure 1 in which the metal member 2 and the resin member 3 are mechanically joined by an anchor effect, the joint strength between the metal member 2 and the resin member 3 is stabilized.

Therefore, by controlling the materials of the metal member 2 and the resin member 3 and the shape of the concave portion A, the bonding strength between the metal member 2 and the resin member 3 can be guaranteed. In addition, the molten or plasticized resin P flows into the concave portion A without gaps and fills the concave portion A without any gaps, so that the metal member 2 and the resin member 3 are bonded together with resin breaking strength. Body 1 can be provided.

Furthermore, in the step of forming the concave portions, the holes and grooves perpendicular to the surface E of the flat metal member 2A are formed, so that the processing equipment for forming the holes and grooves in the surface E of the metal member 2A does not become large-scale. , the processing time can be shortened, so the manufacturing cost can be reduced.

Although the holes 4A to 4N in the description of the above embodiment are round holes, the vertical holes formed in the surface E of the flat metal member 2A in the recess forming step are not limited to round holes. The holes may be slots or screw holes. When the hole is to be a tapped hole, for example, in the concave portion forming step, a drill press, machining center, or the like is used to apply rotation and feed to the drill to form a round hole as a pilot hole, and then the drill press, machining center, or the like is used. Tapping is performed by tapping. By forming the holes as screw holes, the bonding strength between the metal member 2 and the resin member 3 can be improved.

All of the descriptions of the above embodiments are examples, and the present invention is not limited to these. Various modifications and changes may be made without departing from the scope of the invention.

1 Joining structure 2 Metal member 2A Flat metal member 2B Metal member after bending deformation 3 Resin members 4A to 4N Holes 5A to 5E Groove A Concave portion B Out-of-plane direction C Cavity D Mold E Surface F1 to F5 Hole Central axis G Gate H Hole group P Molten or plasticized resin material R1 to R6 Row S Groove group

Claims (2)

On the surface of a flat metal member,
a concave portion consisting of a plurality of vertical holes, or
a concave portion consisting of a plurality of vertical grooves, or
a recessed portion forming step of forming a recessed portion composed of a plurality of vertical holes and vertical grooves by mechanical removal processing;
The flat metal member that has undergone the concave portion forming step,
All or part of the plurality of holes, or the plurality of grooves, or the plurality of holes and the grooves, which are the concave portions, are bent in the out-of-plane direction so as to form an undercut shape as a whole. A bending step of bending and deforming the metal member into a metal member after bending deformation;
Using a mold having a cavity on the surface side of the metal member after the bending deformation that has undergone the bending step, where the concave portion is formed, a molten or plasticized resin material is introduced into the cavity from the gate of the mold. an injection molding step of molding a resin member into the shape of the cavity by injecting it into the cavity;
A method for manufacturing a joint structure between a metal member and a resin member, comprising:
The bending step is performed by sheet metal press working,
A method for manufacturing a joint structure of a metal member and a resin member according to claim 1 .

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