JP7452045B2 - Composite molded body and its manufacturing method - Google Patents

Description

The present disclosure relates to a composite molded article and a method for manufacturing the same.

For the purpose of reducing the weight of various molded bodies used in vehicles, etc., dissimilar metal joining of steel materials and lightweight metal materials such as aluminum alloys and magnesium alloys, dissimilar metal joining of steel materials or lightweight metal materials and resin materials, etc. is being considered. Further weight reduction can be expected by joining dissimilar materials such as steel material or lightweight metal material and resin material.

Therefore, a method of manufacturing a new composite molded body by joining and integrating a metal molded body and a resin molded body is being considered.
For example, as a method that can increase processing speed and increase bonding strength in different directions, a continuous wave laser is used to irradiate the surface of a metal molded object with laser light at an irradiation speed of 2000 mm/sec or more. A method for roughening the surface of a metal molded body and a method for manufacturing a composite molded body have been proposed, in which the surface of the metal molded body is roughened by continuous irradiation with .
In Patent Document 1 and Patent Document 2, a composite molded body is manufactured by roughening the surface of the metal molded body and then joining and integrating the metal molded body and the resin molded body by injection molding.

Patent No. 5774246 Patent No. 5701414

Composite molded bodies formed by the methods described in Patent Document 1 and Patent Document 2 tend to generate residual stress due to mold shrinkage of the resin after molding. When residual stress occurs due to molding shrinkage, the bonding strength between the metal molded body and the resin molded body may decrease.
The present disclosure has been made in view of the above-mentioned conventional circumstances, and aims to provide a method for manufacturing a composite molded body that is less likely to generate residual stress, and a composite molded body that has high bonding strength.

Specific means for achieving the above object are as follows.
<1> A first resin material is primarily injected into a cavity formed by a first mold and a second mold, and the first resin material is provided at the bottom and the peripheral edge of the bottom, and from the peripheral edge to the a molding step of molding a resin member having a side wall portion protruding in the thickness direction of the bottom portion, and a first joint edge including a first recessed portion at the tip of the side wall portion;
In a state where the resin member is held in the first mold, the surface of the second recess includes the first joint edge and a second recess held in the second mold. by relative movement of the first mold and the second mold. The resin member and the metal member contact each other to form a hollow part, and the space formed by the first recess and the second recess is connected to the first joining edge and the second recess. A moving step of forming the contact point with the joining edge;
a joining step of secondarily injecting a second resin material into the space and filling the space with the second resin material;
A method for producing a composite molded body having the following.
<2> The resin member has a first fitting portion closer to the hollow portion than a location of the first joint edge where the first recess is provided,
the metal member has a second fitting portion closer to the hollow portion than a location of the second joint edge where the second recess is provided;
The method for manufacturing a composite molded body according to <1>, wherein the space is filled with the second resin material in a state where the first fitting part and the second fitting part are fitted.
<3> A bottom part, and a side wall part that is provided on a peripheral edge of the bottom part and protrudes from the peripheral edge part in the thickness direction of the bottom part, and includes a first recess at the tip of the side wall part. a resin member provided with one joining edge;
including a second recess, at least a part of the surface of the second recess has a second joint edge that is a roughened surface having unevenness, and forms a hollow part with the resin member; a metal member in which the second joint edge is placed in contact with the first joint edge so that a space is formed between the first recess and the second recess;
a resin bonding material filling the space;
A composite molded body having
<4> A first resin material is primarily injected into a cavity formed by a first mold and a second mold to form a first case member having a third joint edge and a fourth joint edge. a molding step of collectively forming a second case member having a second case member;
With the first case member held in the first mold and the second case member held in the second mold, the third joint edge and the fourth joint edge are connected. , a moving step of bringing the first mold and the second mold into contact by relative movement to form a hollow part by the first case member and the second case member;
a joining step of joining a contact point between the third joining edge and the fourth joining edge by secondary injection of a second resin material;
At least one of the first case member and the second case member arranges at least a portion of the metal insert member within the hollow portion by contacting the third joint edge and the fourth joint edge. It has a notch that forms a fixing hole for the
In the moving step, the metal insert member is held in the fixing hole,
At least a part of the part of the metal insert member held by the fixing hole is a roughened surface having unevenness, and the part of the metal insert member held by the fixing hole is made of a roughened surface. A method for manufacturing a composite molded body, which is bonded using the second resin material in a bonding step.
<5> A first case member made of resin having a third joint edge; and a resin having a fourth joint edge, the fourth joint edge contacting the third joint edge to form a hollow portion. and a metal insert member at least partially disposed within the hollow portion,
At least one of the first case member and the second case member arranges at least a portion of the metal insert member in the hollow portion by contacting the third joint edge and the fourth joint edge. It has a notch part that forms a fixing hole for
At least a part of the part of the metal insert member held by the fixing hole is a roughened surface having unevenness,
A composite molded body in which a contact portion between the third joint edge and the fourth joint edge and a portion held in the fixing hole of the metal insert member are joined with a resin bonding material.

According to the present disclosure, it is possible to provide a method for manufacturing a composite molded body that is less likely to cause residual stress, and a composite molded body that has high bonding strength.

FIG. 3 is a cross-sectional view of a section of the water jacket 10 where a heat sink 12 is provided, as seen from a cut surface taken in a direction perpendicular to the flow direction of the refrigerant. FIG. 2 is an end view of a mold for forming the water jacket main body 14, showing the mold in an opened state. FIG. 2 is an end view of a mold for forming the water jacket main body 14, showing a state in which the mold is closed during primary injection. FIG. 7 is an end view for explaining the moving process, and is a diagram showing the state after the second mold 52 has slid in the direction of arrow A. FIG. It is an end view for explaining a movement process, and is a figure showing the state where the first mold 50 and the second mold 52 are mold-closed after the second mold 52 slides. FIG. 2 is a perspective view of a composite molded body 110. 7 is an end view taken along line AA in FIG. 6. FIG.

Hereinafter, the composite molded article of the present disclosure and its manufacturing method will be described with reference to the drawings. Note that the sizes of the members in each figure are conceptual, and the relative size relationships between the members are not limited thereto. Further, members having substantially the same functions are given the same reference numerals throughout the drawings, and overlapping explanations may be omitted.
The present disclosure is not limited to the following embodiments. In the following embodiments, the constituent elements (including elemental steps and the like) are not essential unless otherwise specified. The same applies to numerical values and their ranges, and they do not limit the present disclosure.

In this disclosure, the term "step" includes not only a step that is independent from other steps, but also a step that cannot be clearly distinguished from other steps, as long as the purpose of the step is achieved. .
In the present disclosure, numerical ranges indicated using "~" include the numerical values written before and after "~" as minimum and maximum values, respectively.
In the numerical ranges described step by step in this disclosure, the upper limit or lower limit described in one numerical range may be replaced with the upper limit or lower limit of another numerical range described step by step. .
In the present disclosure, "(meth)acrylic" means at least one of acrylic and methacryl.

<First embodiment>
The composite molded article of the first embodiment has a bottom, and a side wall that is provided at a peripheral edge of the bottom and projects from the peripheral edge in the thickness direction of the bottom, and has a side wall that extends from the peripheral edge in the thickness direction of the bottom. a resin member provided with a first joining edge including a first recess; and a second resin member including a second recess, wherein at least a portion of the surface of the second recess is a roughened surface having an uneven surface. The second joint edge is connected to the first recess so that a hollow part is formed with the resin member, and a space is formed between the first recess and the second recess. It has a metal member disposed in contact with the joining edge, and a resin joining material filling the space.
In the composite molded article of the first embodiment, a resin-resin bond is formed between the resin bonding material and the resin member. Further, resin-metal bonding occurs between the resin bonding material and the metal member. Therefore, the composite molded article of the first embodiment has high bonding strength.

FIG. 1 shows a section of a water jacket 10, which is an example of the composite molded product of the first embodiment, where a heat sink 12, which is an example of a metal member, is provided, in a direction perpendicular to the flow direction of the refrigerant. It is a sectional view seen from the surface.

The water jacket 10 includes a heat sink 12 and a water jacket main body 14 that is an example of a resin member. The heat sink 12 and the water jacket main body 14 are integrated to form a hollow portion 16.

The water jacket main body 14 includes a bottom portion 18 and a side wall portion 20 that is provided at the peripheral edge of the bottom portion 18 and extends from the peripheral edge of the bottom portion 18 in the thickness direction of the bottom portion 18. A first joint edge 24 including a first recess 22 is provided at the tip of the side wall portion 20 .

The heat sink 12 includes a plate-shaped support portion 26 and a plurality of plate-shaped fins 28 that stand up from the support portion 26 in the direction of the hollow portion 16 . The plurality of fins 28 are arranged substantially horizontally along the flow direction of the refrigerant.

A second joint edge 32 including a second recess 30 is provided around the support portion 26 . At least a portion of the surface of the second recess 30 is a roughened surface 33 having unevenness.

The first joint edge 24 of the water jacket main body 14 and the second joint edge 32 of the heat sink 12 contact each other to form a joint portion 34. Further, a space 36 is formed in the joint portion 34 by the first recess 22 and the second recess 30. Note that in FIG. 1, the space 36 is filled with a resin bonding material 40, which will be described later.

The first recess 22 is provided around the entire circumference of the first joining edge 24. Further, the second recess 30 is provided around the entire circumference of the second joining edge 32. Therefore, the space 36 is formed around the entire circumference of the joint portion 34.

The support portion 26 is provided with a gate port 38 that communicates with the space 36, and the space 36 communicates with the outside via the gate port 38.

In the first embodiment, the space 36 is formed around the entire circumference of the joint 34, but the space 36 may be formed in at least a portion of the joint 34. Further, the space 36 may be one or a plurality of spaces independent of each other. When the joint portion 34 has a plurality of mutually independent spaces 36, a plurality of gate ports 38 communicating with each of the spaces 36 are provided in the support portion 26. When the joint portion 34 has a plurality of mutually independent spaces 36, the first recess 22 and the second recess 30 corresponding to each space 36 are connected to the first joint edge 24 and the second joint edge 32, respectively. provided.

The space 36 is filled with a resin bonding material 40 for bonding the water jacket main body 14 and the heat sink 12 together. The resin bonding material 40 is firmly bonded to the water jacket main body 14 made of resin. Furthermore, since at least a portion of the surface of the second recess 30 is a roughened surface 33 having irregularities, the resin bonding material 40 is firmly bonded to the heat sink 12 via the roughened surface 33. As a result, the resin bonding material 40 filled in the space 36 firmly bonds the water jacket main body 14 and the heat sink 12.

In the first joint edge 24, a fitting convex portion 42, which is a first fitting portion, is provided closer to the hollow portion 16 than the location where the first recess 22 is provided. Further, in the second joining edge 32, a fitting recess 44, which is a second fitting portion, is provided closer to the hollow portion 16 than the location where the second recess 30 is provided. The fitting convex portion 42 and the fitting recess 44 fit together to form a fitting portion 45 .

The fitting protrusion 42 may be provided along the location where the first recess 22 is provided. For example, when the first recess 22 is provided around the entire circumference of the first joint edge 24, it is preferable that the fitting convex portion 42 is provided around the entire circumference of the first joint edge 24. On the other hand, when the first recess 22 is provided in a part of the first joint edge 24, the fitting protrusion 42 may be provided at a location adjacent to the first recess 22.
Further, the fitting recess 44 may be provided along the location where the second recess 30 is provided. For example, when the second recess 30 is provided all around the second joining edge 32, it is preferable that the fitting recess 44 is provided all around the second joining edge 32. On the other hand, when the second recess 30 is provided in a part of the second joint edge 32, the fitting recess 44 may be provided at a location adjacent to the second recess 30.

A flange 46 having an L-shaped cross section is provided on a surface of the side wall portion 20 of the water jacket body 14 that is opposite to the surface that contacts the hollow portion 16 . The flange 46 may be provided around the entire circumference of the side wall portion 20 or may be provided on a portion of the side wall portion 20.

A refrigerant is supplied to the hollow part 16 of the water jacket 10 from a refrigerant supply means (not shown), and a power semiconductor, a capacitor, etc. disposed on the side opposite to the side where the fins 28 are provided in the support part 26 of the heat sink 12 is supplied with a refrigerant. Electronic components and bus bars that connect these electronic components are cooled. Since the composite molded body of the first embodiment has high bonding strength, even if the composite molded body is deformed or the like, peeling between the resin member and the metal member at the joint portion 34 is suppressed. Therefore, leakage of refrigerant from the joint portion 34 is less likely to occur.

The roughened surface of the metal member may be provided on the entire surface of the second recess 30 or may be provided on a part of the surface of the second recess 30. Note that the roughened surface of the metal member may be provided at locations other than the surface of the second recess 30, or may not be provided at locations other than the surface of the second recess 30.
When the roughened surface is provided on a part of the surface of the second recessed portion 30, the surface of the second recessed portion 30 has a smooth portion that is not roughened and an uneven portion corresponding to the roughened surface; It is preferable that the uneven portion has a plurality of convex portions that protrude to a position higher than the reference surface when the surface of the reference surface is used as the reference surface. Since the uneven portion has a plurality of convex portions that protrude to a position higher than the reference surface, the heat sink 12 can be firmly bonded to the resin bonding material 40 via the convex portions.

The height of the convex portion from the reference plane may be in the range of 15 μm to 1000 μm, may be in the range of 15 μm to 50 μm, may be in the range of 50 μm to 500 μm, or may be in the range of 500 μm to 1000 μm. There may be.
The density of the convex portions in the uneven portion is preferably 5 pieces/mm ² to 50 pieces/mm ² , more preferably 10 pieces/mm ² to 30 pieces/mm ² , and 10 pieces/mm 2 to 30 pieces/mm ² . More preferably, the number is 25 pieces/mm ² .

The method of forming a roughened surface having irregularities on a metal member is not particularly limited. Examples of methods for forming a roughened surface on a metal member include a method using chemical treatment such as etching, a laser roughening method in which the surface of the metal member is irradiated with laser light to create irregularities, and the like. Among these, the laser roughening method is preferred because it can easily form convex portions that protrude to a higher position than the reference surface.

Below, various conditions will be described when employing a method of forming a roughened surface by irradiating the surface of a metal member with laser light.
The following various conditions are appropriately set in consideration of the type of metal constituting the metal member, the average height of the convex portion from the reference plane, etc.

When providing a roughened surface by irradiating the surface of a metal member with a laser beam, a pulsed laser or a continuous wave (CW) laser may be used. When using a CW laser, the CW laser may be a modulated CW laser that periodically changes the output of the laser.

When using a CW laser, the irradiation speed (scan speed) of the CW laser is not particularly limited.
The irradiation speed of the CW laser is preferably 100 mm/sec to 2000 mm/sec.

Laser irradiation output is not particularly limited.
For example, when using a CW laser, the laser output is preferably 6W to 500W.

The laser spot diameter is not particularly limited.
For example, the laser spot diameter is preferably 10 μm to 50 μm.

When using a modulated CW laser, the modulation method may be a sine wave, a triangular wave, or a rectangular wave.
The frequency of the modulated CW laser is preferably 1000Hz to 10000Hz.
In a modulated CW laser, the minimum value of the laser output when the maximum value of the laser output is 100 is preferably 30 or more and less than 100, more preferably 50 to 95, and preferably 80 to 90. More preferred.

When irradiating the surface of a metal member with a laser beam, a roughened surface may be provided by wobbling.
Furthermore, a portion that has been irradiated once with laser light may be repeatedly irradiated with laser light. When repeatedly irradiating with laser light, the number of repetitions is preferably 1 to 40 times.

Lasers include ruby lasers, YAG (yttrium aluminum garnet) lasers, solid lasers such as titanium sapphire lasers, liquid lasers such as dye lasers, helium neon lasers, argon ion lasers, carbon dioxide lasers, nitrogen lasers, excimer lasers, etc. Gas lasers, semiconductor lasers, fiber lasers, etc. can be used.
The laser may be a green laser.

When providing a roughened surface by irradiating the surface of a metal member with a laser beam, compressed air may be supplied to a portion of the surface of the metal member that is irradiated with the laser beam. The pressure of the supplied compressed air is preferably 0.2 MPa to 0.5 MPa from the viewpoint of efficiently removing metal powder generated by laser beam irradiation.

When the laser beam is applied in a straight line, the scanning interval of the laser beam is preferably larger than the spot diameter of the laser beam.

The metal constituting the metal member used in the first embodiment can be appropriately selected depending on the use of the composite molded body.
Examples of metals constituting the metal member include iron, aluminum, zinc, titanium, copper, magnesium, and alloys containing these. Examples of the alloy include various stainless steels and copper-zinc alloys (brass).
The second joining edge of the metal member may be subjected to surface treatment such as plating or alumite treatment.

The resin constituting the resin member used in the first embodiment is not particularly limited as long as it can be bonded to a metal member, and conventionally known resins may be used as appropriate depending on the use of the composite molded product. It can be used selectively.
Examples of the resin include thermosetting resins, thermoplastic resins, and elastomers.

Specific examples of thermosetting resins include phenol resin, unsaturated imide resin, cyanate resin, isocyanate resin, benzoxazine resin, oxetane resin, amino resin, unsaturated polyester resin, allyl resin, dicyclopentadiene resin, silicone resin, Examples include triazine resin, melamine resin, resorcinol resin, and epoxy resin.
Specific examples of thermoplastic resins include polyimide resin, polyamideimide resin, polyamide resin, polyetherimide resin, polybenzoxazole resin, polybenzimidazole resin, polystyrene resin, acrylonitrile-butadiene-styrene copolymer resin, and acrylonitrile-styrene copolymer resin. Examples include polymer resins, polyethylene resins, polypropylene resins, polyvinyl chloride resins, polyvinylidene chloride resins, polycarbonate resins, (meth)acrylic resins, polyester resins, polyacetal resins, polyphenylene sulfide resins (PPS), and the like.
Specific examples of elastomers include silicone rubber, styrene butadiene rubber (SBR), nitrile rubber (NBR), urethane rubber, and the like.

The resin member may contain other components other than conventionally known resins depending on the use of the composite molded product. Other components include particulate fillers, fibrous fillers, mold release agents, and the like.

Examples of other components include a curing agent for curing the thermosetting resin, a curing accelerator for accelerating the curing of the thermosetting resin, and a surface treatment agent for modifying the surface of the inorganic material.

The content of components other than the resin contained in the resin member may be appropriately set depending on the use of the composite molded article.

The composite molded body of the first embodiment may be manufactured by any method, but from the viewpoint of reducing residual stress, it is preferably manufactured by the method for manufacturing the composite molded body of the first embodiment described later. preferable.

The method for manufacturing a composite molded article according to the first embodiment includes primary injection of a first resin material into a cavity formed by a first mold and a second mold, and a bottom part and a periphery of the bottom part. a side wall part provided at the bottom part and extending from the peripheral edge part in the thickness direction of the bottom part, and a resin member having a first joint edge including a first recessed part at the tip of the side wall part. a molding step of molding the first joining edge and a second recess held in the second mold with the resin member held in the first mold; The second joint edge of a metal member having a second joint edge in which at least a part of the surface of the second recess is a roughened surface having irregularities, and the first mold and the second joint edge A hollow part is formed by the resin member and the metal member by relative movement of the molds, and a space formed by the first recess and the second recess is connected to the first recess. a moving step of forming a contact point between the joining edge and the second joining edge; and a joining step of secondarily injecting a second resin material into the space to fill the space with the second resin material. and has.
According to the method for manufacturing a composite molded body of the first embodiment, residual stress is less likely to occur in the composite molded body.

First, a mold used in the method for manufacturing a composite molded body according to the first embodiment will be described.
FIG. 2 is an end view of a mold for forming the water jacket body 14 used in the method for manufacturing a composite molded body according to the first embodiment, showing an opened state. FIG. 3 is an end view of a mold for forming the water jacket main body 14 used in the method for manufacturing a composite molded body according to the first embodiment, showing a state in which the mold is closed during primary injection.

As shown in FIGS. 2 and 3, the mold 48 is provided in a molding machine (not shown) that performs die slide injection (DSI) molding. The mold 48 includes a first mold 50 and a second mold 52. The first mold 50 and the second mold 52 are made of a metal material such as stainless steel.

The first mold 50 is provided with a cavity portion 54 for forming the external shape of the water jacket body 14. A recess corresponding to the external shape of the water jacket main body 14 is formed in the cavity portion 54 .
The second mold 52 is provided with a core portion 56 for forming the internal shape of the water jacket body 14 and the first joint edge 24, and a housing portion 58 for holding the heat sink 12. A convex portion corresponding to the internal shape of the water jacket main body 14 and the first joint edge 24 is formed in the core portion 56 . Note that in FIGS. 2 to 5, the fins 28 forming the heat sink 12 are omitted.

As shown in FIG. 3, when the first mold 50 and the second mold 52 are closed before primary injection, the cavity part 54 of the first mold 50 and the second mold 52 are closed. A cavity 60 for the water jacket body 14 is formed by the core portion 56 of the water jacket body 14 .

A gate 62 for injecting a first resin material for primary injection into a cavity 60 is formed in the first mold 50 . The position of the injection port of the gate 62 is not particularly limited, and examples include the location where the flange 46 is provided in the water jacket main body 14, the bottom portion 18, the side wall portion 20, and the like.

Furthermore, a gate for injecting a second resin material for secondary injection is formed in the first mold 50. In this embodiment, the gate 62 for injecting the first resin material for primary injection also serves as the gate for injecting the second resin material for secondary injection. The gate for injecting the second resin material may be provided independently of the gate 62 for injecting the first resin material for primary injection.

In addition to the mold 48, the molding machine includes an injection machine 64 that injects a first resin material for primary injection and a second resin material for secondary injection from a gate 62, a first mold 50, and a second resin material. A first driving means for switching between closing and opening the mold 52, and a first driving means for switching the second mold 52 to the first mold when the first mold 50 and the second mold 52 are open. A second driving means for sliding movement relative to the mold 50 is provided.
Further, the molding machine includes a control section for controlling the operations of various devices such as the injection machine 64, the first drive means, the second drive means, and the like. The control unit includes a nonvolatile memory that stores a program, a volatile memory that is a temporary storage area for executing the program, an input/output port, a processor that executes the program, and the like.

Next, the operation of the molding machine used to carry out the method for manufacturing a composite molded body according to the first embodiment will be explained.
In the first embodiment, the method for manufacturing a composite molded body is carried out by the control unit of the molding machine executing a program to control the operations of the first drive means, the second drive means, the injection machine 64, and the like.

Before the forming step of forming the water jacket main body 14 using a molding machine, the first mold 50 and the second mold 52 are in an open state, as shown in FIG. At this stage, the heat sink 12 is held in the accommodation portion 58 of the second mold 52 such that the side of the support portion 26 of the heat sink 12 on which the fins 28 are provided faces the first mold 50 side. There is.

A forming step is then performed. That is, at the start of resin molding of the water jacket main body 14, the first mold 50 and the second mold 52 are closed as shown in FIG.

After the mold is closed, the first resin material is primarily injected into the cavity 60 from the injection machine 64 through the gate 62. As a result, the water jacket main body 14 is formed.

Then, a moving step is performed. In the moving process, with the water jacket body 14 held in the first mold 50, the first joint edge 24 of the water jacket body 14 and the second joint edge 32 of the heat sink 12 are The mold 50 and the second mold 52 are brought into contact by relative movement. In this embodiment, the relative movement between the first mold 50 and the second mold 52 specifically includes sliding movement of the second mold 52 in the direction of arrow A shown in FIG. The first mold 50 and the second mold 52 shown in FIG. 5 are closed.

By closing the first mold 50 and the second mold 52 shown in FIG. 5, a hollow portion 16 is formed by the heat sink 12 and the water jacket main body 14.
Further, the first joint edge 24 of the water jacket main body 14 and the second joint edge 32 of the heat sink 12 contact each other to form a joint portion 34. Thereby, a space 36 is formed in the joint portion 34 by the first recess 22 and the second recess 30.

After the water jacket main body 14 is formed in the forming process and before the first joining edge 24 of the water jacket main body 14 and the second joining edge 32 of the heat sink 12 come into contact in the moving process, injection molding is performed. The temperature of the water jacket body 14 is lower than the temperature of the resin when it is primarily injected from the injection machine 64 into the cavity 60 via the gate 62. When the temperature of the water jacket body 14 decreases, the water jacket body 14 may contract, and the water jacket body 14 may be deformed.

In this embodiment, since the water jacket main body 14 is provided with the flange 46 having an L-shaped cross section, the flange 46 is prevented from being caught on the first mold 50 and the side wall portion 20 is prevented from falling toward the hollow portion 16 side. be done. Therefore, the accuracy of joining the water jacket main body 14 and the heat sink 12 via the first joining edge 24 and the second joining edge 32 is improved, and the first recess 22 and the second recess 30 are formed. The space 36 can be formed with high precision.

Next, a bonding step is performed. In the bonding process, a second resin material corresponding to the resin bonding material 40 is secondarily injected into the space 36 from the injection machine 64 through the gate 62 and the gate port 38 of the support portion 26 . The secondary injection resin bonding material 40 fills the space 36, thereby bonding the water jacket main body 14 and the heat sink 12, thereby obtaining the water jacket 10.

Further, in this embodiment, the second resin material is filled in the space 36 in a state where the fitting convex part 42 and the fitting recess 44 are fitted to form the fitting part 45, so that the secondary injection can be performed. The pressure prevents the side wall 20 from deforming or breaking.

Examples of the second resin material include thermosetting resins, thermoplastic resins, elastomers, etc., which have already been described as resins constituting the resin member.
The second resin material used as the resin bonding material 40 may be the same as or different from the first resin material.

<Second embodiment>
The composite molded body of the second embodiment includes a first case member made of resin having a third joint edge, and a fourth joint edge, the fourth joint edge contacting the third joint edge. a second case member made of resin to form a hollow part; and a metal insert member at least partially disposed within the hollow part, and at least one of the first case member and the second case member The third joint edge and the fourth joint edge come into contact with each other to form a fixing hole for arranging at least a portion of the metal insert member in the hollow portion. At least a part of the metal insert member held by the fixing hole is a roughened surface having unevenness, and the third joint edge and the fourth joint edge are in contact with each other. The location and the location held by the fixing hole of the metal insert member are bonded with a resin bonding material.
In the composite molded article of the second embodiment, resin-metal bonding occurs between the resin bonding material and the metal insert member. Therefore, the composite molded body of the second embodiment has high bonding strength.

Hereinafter, the composite molded body 110 of the second embodiment will be described in detail based on FIGS. 6 and 7. 6 is a perspective view of the composite molded body 110, and FIG. 7 is an end view taken along line AA in FIG. 6.

The composite molded body 110 includes a first case member 114 made of resin, a second case member 116 made of resin, and a metal rod 112.
The first case member 114 includes a bottom portion 118 and a side wall portion 119 that is provided at the peripheral edge of the bottom portion 118 and projects from the peripheral edge of the bottom portion 118 in the thickness direction of the bottom portion 118. A third joining edge 124 is provided at the tip of the side wall portion 119.
The second case member 116 , like the first case member 114 , has a bottom 121 and a side wall 120 that is provided at the periphery of the bottom 121 and protrudes from the periphery of the bottom 121 in the thickness direction of the bottom 121 . have A fourth joining edge 128 is provided at the tip of the side wall portion 120.

The third joint edge 124 of the first case member 114 and the fourth joint edge 128 of the second case member 116 contact each other to form a joint portion 130. Further, the first case member 114 and the second case member 116 are integrated at a joint portion 130 to form a hollow portion 132.

Each of the joining edge 124 of the first case member 114 and the joining edge 128 of the second case member 116 has a structure in which at least a portion of the metal rod 112 is inserted into the hollow portion 132 when the joining edge 124 and the joining edge 128 come into contact with each other. A notch 136 and a notch 137 are provided to form a fixing hole 134 for placement. When the joining edge 124 of the first case member 114 and the joining edge 128 of the second case member 116 come into contact with each other, a fixing hole 134 is formed by the notch 136 and the notch 137.
The fixing hole 134 holds the metal rod 112. A portion of the metal rod 112 held in the fixing hole 134 is placed within the hollow portion 132.

A flange 142 and a flange 144 each having an L-shaped cross section are provided on the side surface of the side wall portion 119 and the side wall portion 120 that is opposite to the surface that contacts the hollow portion 132 . In the second embodiment, the flange 142 and the flange 144 are provided around the entire circumference of the side wall portion 119 and the side wall portion 120. Note that the flange 142 and the flange 144 may be provided on a portion of the side wall portion 119 and the side wall portion 120.
The flange 142 and the flange 144 are provided with a third recess 122 and a fourth recess 126, respectively.
In the joining edge 124 and the joining edge 128, a fitting convex portion is provided at a location closer to the hollow portion 132 than the location where the third recess 122 and the fourth recess 126 are provided and in contact with the metal rod 112, respectively. 146 and a fitting protrusion 148 are provided. Furthermore, a fitting recess 150 is provided at a location corresponding to the fitting protrusion 146 and the fitting protrusion 148 on the metal rod 112. 148 and the fitting recess 150 fit into each other to form a fitting part 152. The fitting recess 150 is a groove provided in the circumferential direction of the metal rod 112.

A space (not shown) is formed by the third recess 122 and the fourth recess 126 in a portion of the joint portion 130 other than the portion where the fixing hole 134 is formed. As shown in FIG. 7, a third recess 122 and a fourth recess 126 are arranged around the metal rod 112 held in the fixing hole 134 so as to surround the metal rod 112. Therefore, a space is formed around the metal rod 112 by the third recess 122 and the surface of the metal rod 112, and a space is formed by the fourth recess 126 and the surface of the metal rod 112. A space (not shown) formed by the third recess 122 and the fourth recess 126 , a space formed by the third recess 122 and the surface of the metal rod 112 , and the fourth recess 126 and the metal rod 112 The space formed by the surface is filled with the previously described resin bonding material 40, which corresponds to the second resin material. That is, the third joining edge 124 and the fourth joining edge 128 are joined by secondary injection of the resin joining material 40, which is the second resin material, at the joining portion 130, which is the contact location. The second resin material is filled into the spaces through gate ports (not shown) communicating with these spaces.

The third recess 122 is provided around the entire periphery of the flange 142. The fourth recess 126 is provided around the entire periphery of the flange 144. Therefore, a space (not shown) is formed around the entire circumference of the joint portion 130. In addition, although the second embodiment refers to a mode in which a space is formed around the entire circumference of the joint 130, as in the first embodiment, the space only needs to be formed in at least a part of the joint 130. . Further, the number of spaces may be one or a plurality of spaces independent of each other.

At least a portion of the metal rod 112 held by the fixing hole 134 is a roughened surface 139 having unevenness. Therefore, the resin bonding material 40 is firmly bonded to the metal rod 112 via the roughened surface 139. Further, the resin bonding material 40 is firmly bonded to the first case member 114 and the second case member 116 made of resin. As a result, the portion of the metal rod 112 held by the fixing hole 134 is firmly joined to the first case member 114 and the second case member 116 by the resin bonding material 40 filled in the space.
Note that the physical properties, formation method, etc. of the roughened surface 139 on the metal rod 112 are the same as in the first embodiment.

In the second embodiment, the metal rod 112 is used as the metal insert member, but the metal insert member is not particularly limited. It is fine as long as it is suitable. Examples of the metal insert member include a rod heater.

The composite molded body of the second embodiment may be manufactured by any method, but from the viewpoint of reducing residual stress, it is preferably manufactured by the method for manufacturing the composite molded body of the second embodiment described below. preferable.

The method for manufacturing a composite molded article according to the second embodiment includes primary injection of a first resin material into a cavity formed by a first mold and a second mold, and a third joining edge. a molding step of collectively forming a first case member and a second case member having a fourth joining edge; the first case member is held in the first mold; While the second case member is held, the third joint edge and the fourth joint edge are brought into contact by relative movement of the first mold and the second mold, and the A moving step of forming a hollow part between the first case member and the second case member and a contact point between the third joint edge and the fourth joint edge are performed by secondary injection of a second resin material. a joining step of joining at least one of the first case member and the second case member by contacting the third joining edge and the fourth joining edge with each other, the metal insert a notch portion forming a fixing hole for arranging at least a portion of the member in the hollow portion, the metal insert member being held in the fixing hole in the moving step, and the metal insert member being held in the fixing hole in the moving step; At least a part of the part of the member held by the fixing hole is a roughened surface having unevenness, and the part where the metal insert member is held by the fixing hole is The second resin material is used for joining.

The molding step, the moving step, and the joining step in the method for manufacturing a composite molded body of the second embodiment can be performed by DSI molding. In addition, in order to hold the metal insert member in the fixing hole during the moving process, for example, the metal insert member is placed in the notch in the first case member or the second case member using a robot arm or the like, and then The third joint edge of the first case member and the fourth joint edge of the second case member are brought into contact with each other by relative movement of the first mold and the second mold, thereby forming a fixing hole and also forming a fixing hole. The metal insert member may be held in the hole.
The structure of the mold etc., the operation of the mold etc., the type of resin material, etc. in the method for manufacturing a composite molded body of the second embodiment are based on the known DSI molding technology and the method for manufacturing a composite molded body of the first embodiment. You can refer to the contents of

Hereinafter, the degree of distortion of the composite molded body was analyzed by computer simulation, taking as an example the case where the surface of the second recess included in the second joint edge of the metal member was not made into a roughened surface.

The stress generation situation of the analytical model of the following composite molded body was determined by computer simulation.
As analysis model 1, a rectangular parallelepiped with a hollow part and dimensions of 200 mm x 150 mm x 30 mm was used, the cross-sectional shape of which was the same as that of FIG. 1 except that the flange 46, gate port 38, and fin 28 were not present. One side of the rectangular parallelepiped was made of a copper material measuring 200 mm x 150 mm x 3 mm, and the other five sides were made of a PPS housing having a wall thickness of 5 mm and containing 30% by mass of glass filler. The cross-sectional diameter of the space 36 in FIG. 1 was 2 mm. The resin bonding material (second resin material) filling the space 36 was PPS. The casing and the copper material are bonded to each other via the resin bonding material 40 on the surfaces (joint surfaces) of the first recess 22 and the second recess 30 in the joint 34, and the casing and the copper material are bonded to each other at other locations. Although they are in contact with each other, they are not bonded (not fixed).
The joint surface is restrained with the temperature of the resin part (casing) and copper material being 150°C and the temperature of the resin part (resin bonding material) being 320°C, and the temperature of the resin part (casing and resin bonding material) and copper material is The stress generated in the joint 34 when the temperature was changed to 20°C was determined using simulation software (SOLIDWORKS Simulation, manufactured by DASSAULT SYSTEMES), and the maximum was 112.8 MPa, and the maximum deformation was 0.07 mm. Met.

As analysis model 2, a rectangular parallelepiped similar to analysis model 1 was adopted, except that the space 36 was not provided and all the points where the casing and the copper material came into contact were used as joint surfaces. Bonding when the temperature of the resin part (casing) is 320°C and the temperature of the copper material is 150°C, the joint surface is restrained, and the temperature of the resin part (casing) and copper material is changed to 20°C. When the stress generated in the part was determined in the same manner as in the case of analysis model 1, the maximum was 291.6 MPa, and the maximum deformation amount was 0.55 mm.
In the case of analysis model 2 in which the casing and the copper material are joined by one molding, all the stress due to molding shrinkage of the resin is applied to the joint. On the other hand, in the present disclosure, at the time of bonding with the second resin material (resin bonding material), the casing, which is a primary molded product, is restrained in a state where the shrinkage is progressing. Only stress is applied to the joint.
Therefore, by molding the molded product taken out from the mold using the manufacturing method of the present disclosure, residual stress can be reduced. The analysis results showed that the stress decreased from 291.6 MPa to 112.8 MPa.

10 Water jacket 12 Heat sink 14 Water jacket main body 16 Hollow part 34 Joint part 36 Space 40 Resin bonding material 45 Fitting part 46 Flange 48 Mold 54 Cavity part 56 Core part 58 Accommodation part 60 Cavity 62 Gate 64 Injection machine 110 Composite molded body 112 Metal rod 114 First case member 116 Second case member 132 Hollow part

Claims (4)

A first resin material is primarily injected into a cavity formed by a first mold and a second mold, and a first resin material is provided at a bottom and a peripheral edge of the bottom, and the thickness of the first resin material is increased from the peripheral edge to the bottom. a molding step of molding a resin member having a side wall portion projecting in the direction, and a first joint edge including a first recessed portion at the tip of the side wall portion;
In a state where the resin member is held in the first mold, the surface of the second recess includes the first joint edge and a second recess held in the second mold. by relative movement of the first mold and the second mold. The resin member and the metal member contact each other to form a hollow part, and the space formed by the first recess and the second recess is connected to the first joining edge and the second recess. A moving step of forming the contact point with the joining edge;
a joining step of secondarily injecting a second resin material into the space and filling the space with the second resin material;
has
The resin member has a fitting convex portion, which is a first fitting portion, closer to the hollow portion than the first joint edge where the first recess is provided;
The metal member has a fitting recess that is a second fitting portion closer to the hollow portion than a location of the second joint edge where the second recess is provided,
A method for manufacturing a composite molded body , in which the space is filled with the second resin material in a state where the first fitting part and the second fitting part are fitted . A first joint having a bottom portion, and a side wall portion provided on a peripheral edge of the bottom portion and projecting from the peripheral edge toward the thickness direction of the bottom portion, and including a first recess at a tip of the side wall portion. a resin member provided with an edge;
including a second recess, at least a part of the surface of the second recess has a second joint edge that is a roughened surface having unevenness, and forms a hollow part with the resin member; a metal member in which the second joint edge is placed in contact with the first joint edge so that a space is formed between the first recess and the second recess;
a resin bonding material filling the space;
has
The resin member has a fitting convex portion, which is a first fitting portion, closer to the hollow portion than the first joint edge where the first recess is provided;
The metal member has a fitting recess that is a second fitting portion closer to the hollow portion than a location of the second joint edge where the second recess is provided,
A composite molded body in which the first fitting portion and the second fitting portion are fitted . A first resin material is primarily injected into a cavity formed by a first mold and a second mold, and a first case member having a third joint edge and a second case member having a fourth joint edge are formed. a molding step of collectively forming the two case members;
With the first case member held in the first mold and the second case member held in the second mold, the third joint edge and the fourth joint edge are connected. , a moving step of bringing the first mold and the second mold into contact by relative movement to form a hollow part by the first case member and the second case member;
a joining step of joining a contact point between the third joining edge and the fourth joining edge by secondary injection of a second resin material;
At least one of the first case member and the second case member arranges at least a portion of the metal insert member within the hollow portion by contacting the third joint edge and the fourth joint edge. It has a notch that forms a fixing hole for the
In the moving step, the metal insert member is held in the fixing hole,
At least a part of the part of the metal insert member that is held by the fixing hole is a roughened surface having unevenness, and the part of the metal insert member that is held by the fixing hole is a roughened surface having unevenness. , a fitting recess, which is a groove provided in the circumferential direction of the metal insert member, is provided closer to the hollow portion than the location where the roughened surface is provided, and the third joint edge is connected to the a fitting protrusion that fits into the fitting recess; the fourth joint edge has a fitting protrusion that fits into the fitting recess; and the fitting recess and the fitting protrusion A method for manufacturing a composite molded body, in which a portion of the metal insert member held in the fixing hole is joined with the second resin material in the joining step in a state where the metal insert member is fitted to form a fitting part. . a first case member made of resin having a third joint edge; and a second case member made of resin having a fourth joint edge and forming a hollow portion by contacting the fourth joint edge with the third joint edge. a metal insert member, at least a portion of which is disposed within the hollow portion;
At least one of the first case member and the second case member arranges at least a portion of the metal insert member in the hollow portion by contacting the third joint edge and the fourth joint edge. It has a notch part that forms a fixing hole for
At least a part of the part of the metal insert member held by the fixing hole is a roughened surface having unevenness,
A groove provided in the circumferential direction of the metal insert member at a location in the metal insert member that is held by the fixing hole and closer to the hollow portion than the location where the roughened surface is provided. A certain fitting recess is provided,
The third joining edge has a fitting convex part that fits into the fitting recess, the fourth joining edge has a fitting convex part that fits into the fitting recess, and the fourth joining edge has a fitting convex part that fits into the fitting recess, and and the fitting convex portion are fitted to form a fitting portion, the contact portion between the third joining edge and the fourth joining edge, and the fixing of the metal insert member. A composite molded body whose parts held by holes are joined with a resin bonding material.