KR102304040B1 - Forming method of metal resin composite material, metal resin composite component and its manufacturing method - Google Patents

Abstract

A method of molding a metal-resin composite material having a laminated structure in which metal layers and resin layers are alternately laminated, and the laminated structure is asymmetrical. This molding method divides the metal resin composite material into parts a and b at a position half of the total layer thickness of the metal resin composite material, and sets the total layer thickness of the resin layers present in the a part to Tra, and the total layer thickness of the metal layers present in the a part. Let Tma, the total layer thickness of the resin layers present in the b part be Trb, and the total layer thickness of the metal layers present in the b part be Tmb,
When Tma/Tra>Tmb/Trb, molding is performed by arranging the a-side side on the surface to which the pressing force is applied,
When Tma/Tra<Tmb/Trb, molding is performed by arranging the side b on the surface to which the pressing force is applied,
In the case of Tma/Tra=Tmb/Trb, molding is performed by arranging the side where the metal layer is located on the surface layer or the side close to the metal layer among the a and b portions on the surface to which the pressing force is applied.

Description

A method of molding a metal-resin composite material, a metal-resin composite part, and a method of manufacturing the same

The present disclosure relates to a method for molding a metal resin composite material, and to a metal resin composite part and a method for manufacturing the same.

BACKGROUND ART In recent years, with increasing interest in environmental issues, the spread of environmentally friendly automobiles equipped with secondary batteries, such as electric vehicles and hybrid vehicles, is advancing. In such an environment-conscious vehicle, a method in which a DC current generated from a mounted secondary battery is converted into an AC current through an inverter, and then necessary electric power is supplied to an AC motor to obtain a driving force is often adopted. Therefore, electromagnetic waves are generated due to the switching operation of the inverter or the like. Since electromagnetic waves are an obstacle to in-vehicle sensors, measures are being taken to shield an electromagnetic wave by accommodating an inverter or an inverter together with a battery, a motor, etc., in a housing formed of an aluminum plate having a predetermined coating film on the surface (Patent Document 1). ).

Japanese Patent Laid-Open No. 2003-285002

In recent years, materials used for electromagnetic shielding have been required to be lightweight and capable of being molded into a complex shape (particularly, one that can be molded by following a mold having a complicated shape). However, it cannot be said that the aluminum plate material described in patent document 1 can fully respond to said request|requirement.

On the other hand, as a method for solving the above needs, a method of using an Al vapor-deposited film in which aluminum is vapor-deposited on a resin film, a method of performing electroless plating on a material having good moldability, and the like can be considered. However, although the method using an Al vapor deposition film is inexpensive and has good moldability, the deposited Al layer has a small thickness and low conductivity compared to copper foil, so there is a problem that the electromagnetic wave shielding effect is not sufficient. In addition, the method of electroless plating on a material having good moldability has a problem that the electromagnetic wave shielding effect is not sufficient because the cost is high and it is difficult to increase the thickness of the plating layer.

Then, the present inventors tried to solve the above-mentioned request|requirement, paying attention to the metal-resin composite material which laminated|stacked the metal layer and the resin layer, and ensuring the electromagnetic wave shielding effect by optimizing the structure of the metal layer and the resin layer.

However, although the metal resin composite material has a good electromagnetic wave shielding effect, springback tends to occur in the bent portion (flange portion) during molding processing (eg, protrusion processing or drawing processing), so that the desired dimensional accuracy is sufficient. There is a problem that it cannot be obtained.

Embodiments of the present invention have been made in order to solve the above problems, and an object of the present invention is to provide a method for molding a metal-resin composite material capable of suppressing springback.

Moreover, embodiment of this invention aims at providing the metal-resin composite component with high dimensional accuracy, and its manufacturing method.

As a result of intensive research to solve the above problems, the present inventors have developed a specific laminated structure based on the knowledge that the laminated structure of the metal resin composite material and the direction of application of the pressing force during molding are related to the occurrence of springback. It has been found that the effect of suppressing springback can be improved by molding by applying a pressing force in a specific direction in the metal-resin composite material having, thereby completing the embodiment of the present invention.

That is, an embodiment of the present invention is a method for molding a metal resin composite material having a laminated structure in which metal layers and resin layers are alternately laminated, and the laminated structure is asymmetrical,

The total layer thickness of the resin layers present in the a part is divided into parts a and b at a position half of the total layer thickness of the metal resin composite material, Tra, the total layer thickness of the metal layers present in the a part. Tma, the total layer thickness of the resin layer present in the b part is Trb, and the total layer thickness of the metal layer present in the b part is Tmb,

When Tma/Tra>Tmb/Trb, molding is performed by arranging the a-part side on the surface to which the pressing force is applied,

When Tma/Tra<Tmb/Trb, molding is performed by arranging the b-side side on a surface to which a pressing force is applied,

In the case of Tma / Tra = Tmb / Trb, on the surface to which the pressing force is applied, the side where the metal layer is located on the surface layer or the side close to the metal layer is arranged on the surface of the a part or the b part to perform molding, a metal resin composite A method of forming a material.

Further, an embodiment of the present invention is a method for manufacturing a metal-resin composite part including the above-described method for molding a metal-resin composite material.

Further, an embodiment of the present invention is a metal resin composite part having a laminate structure in which metal layers and resin layers are alternately laminated, and the laminate structure is formed of a metal resin composite material asymmetric,

The total layer thickness of the resin layers present in the a part is divided into parts a and b at a position half of the total layer thickness of the metal resin composite material, Tra, the total layer thickness of the metal layers present in the a part. is Tma, the total layer thickness of the resin layer present in the b part is Trb, and the total layer thickness of the metal layer present in the b part is Tmb,

When Tma/Tra>Tmb/Trb, the side a is disposed on the surface to which the pressing force is applied,

When Tma/Tra<Tmb/Trb, the side b is disposed on the surface to which the pressing force is applied,

In the case of Tma/Tra=Tmb/Trb, the side to which the metal layer is positioned on the surface layer or the side close to the metal layer among the parts a or b is disposed on the surface to which the pressing force is applied.

ADVANTAGE OF THE INVENTION According to embodiment of this invention, the shaping|molding method of the metal-resin composite material which can suppress springback can be provided.

Moreover, according to embodiment of this invention, a metal-resin composite part with high dimensional accuracy, and its manufacturing method can be provided.

1 is a cross-sectional view of a metal resin composite material having a two-layer structure of a metal layer/resin layer.
2 is a cross-sectional view of a metal resin composite material having a three-layer structure of a metal layer/resin layer/metal layer.
3 is a cross-sectional view of a metal resin composite material having a four-layer structure of a metal layer/resin layer/metal layer/resin layer.
4 is a view for explaining a method of applying a pressing force F in the drawing process.
5 is a photograph of the molded article molded in Example 1 and Comparative Example 1.

EMBODIMENT OF THE INVENTION Hereinafter, although preferred embodiment of this invention is demonstrated concretely, referring drawings, this invention is not limited to these and should not be interpreted, Unless it deviates from the summary of this invention, Based on the knowledge of those skilled in the art , various changes and improvements can be made. A plurality of components disclosed in this embodiment can form various inventions by appropriate combinations. For example, some components may be deleted from all the components shown in this embodiment, and the components of another embodiment may be combined suitably.

In the method for molding a metal resin composite material according to an embodiment of the present invention, the metal resin composite material is molded by applying a pressing force from a specific direction according to the type of the laminate structure of the metal resin composite material.

The metal-resin composite material has a laminated structure in which metal layers and resin layers are alternately laminated. A metal resin composite material having such a structure has an electromagnetic wave shielding effect, and therefore can be used as an electromagnetic wave shielding material.

The number of layers in the laminated structure of the metal resin composite material is not particularly limited as long as it is two or more layers, but is preferably 2 to 15 layers, more preferably 2 to 10 layers, still more preferably 2 to 8 layers. Examples of the laminated structure include a two-layer structure of a metal layer/resin layer, a three-layer structure of a resin layer/metal layer/resin layer or a metal layer/resin layer/metal layer, a resin layer/metal layer/resin layer/metal layer or a metal layer/resin layer/metal layer/ A four-layer structure of a resin layer, etc. are mentioned.

The laminate structure of the metal-resin composite material is asymmetric. When the number of layers of the metal-resin composite material is an even number, the laminate structure becomes asymmetric. On the other hand, when the number of layers of the metal resin composite material is an odd number (excluding 1), the laminate structure becomes asymmetric or symmetric. As an example of a symmetrical laminated structure, the case where the thickness of the 1st layer and 3rd layer of a three-layer structure are equal, etc. In addition, as an example of an asymmetric laminated structure, the case where the thickness of the 1st layer and 3rd layer of a three-layer structure differ, etc. are mentioned.

In addition, it is preferable that the laminated structure of the metal resin composite material has two or more metal layers. By setting it as such a structure, since the reflection surface of an electromagnetic wave increases, the electromagnetic wave shielding effect can be improved.

The molding method of the metal resin composite material according to the embodiment of the present invention is performed as follows.

In the laminated structure of the metal resin composite material, the metal resin composite material is divided into two parts a and b at a position of half the thickness of the entire layer. Then, the total layer thickness of the resin layers present in the a part is Tra, the total layer thickness of the metal layers present in the a part is Tma, the total layer thickness of the resin layers present in the b part is Trb, and the metal layer present in the b part. Let the total layer thickness of Tmb be. After that, the direction of application of the pressing force is determined according to each case of the following (1) to (3), and molding is performed.

(1) In the case of Tma/Tra>Tmb/Trb, molding is performed by arranging the a-side side on the surface to which the pressing force is applied.

(2) In the case of Tma/Tra<Tmb/Trb, molding is performed by arranging the b-side side on the surface to which the pressing force is applied.

(3) In the case of Tma/Tra=Tmb/Trb, molding is performed by arranging the side where the metal layer is located on the surface or the side close to the metal layer among the a or b parts on the surface to which the pressing force is applied.

By performing molding while applying a pressing force as described above, the occurrence of springback can be suppressed.

Here, Fig. 1 shows a cross-sectional view of the metal-resin composite material corresponding to the case of (1).

1 is a cross-sectional view of a metal-resin composite material having a two-layer structure of a metal layer 10/resin layer 20. As shown in FIG. When the metal-resin composite material is divided into parts a and b at half the thickness of the entire layer, Tra, Tma, and Trb may be determined as shown in FIG. 1 . In addition, in the metal resin composite material shown in Fig. 1, Tmb becomes zero due to the two-layer structure, but Tmb can be set to be larger than zero when the three-layer or more laminated structure is used.

In order to satisfy the relationship of Tma/Tra>Tmb/Trb, the metal resin composite material of FIG. 1 is molded by arranging the a-side side on the surface to which the pressing force F is applied.

Next, a cross-sectional view of the metal resin composite material corresponding to the case (2) is shown in FIG. 2 .

2 is a cross-sectional view of a metal-resin composite material having a three-layer structure of metal layer 10/resin layer 20/metal layer 10. As shown in FIG. When the metal-resin composite material is divided into parts a and b at half the thickness of the entire layer, Tra, Tma, Tmb, and Trb may be determined as shown in FIG. 2 . Moreover, in the metal resin composite material of FIG. 2, the thickness of the two metal layers 10 is different, and the thickness of the metal layer 10 of part b is set larger than the thickness of the metal layer 10 of part a.

In order to satisfy the relationship of Tma/Tra<Tmb/Trb, the metal resin composite material of FIG. 2 is molded by arranging the b-side side on the surface to which the pressing force F is applied.

Next, a cross-sectional view of the metal resin composite material corresponding to the case of (3) is shown in FIG. 3 .

3 is a cross-sectional view of a metal-resin composite material having a four-layer structure of metal layer 10/resin layer 20/metal layer 10/resin layer 20. As shown in FIG. When the metal-resin composite material is divided into parts a and b at half the thickness of the entire layer, Tra, Tma, Tmb, and Trb may be determined as shown in FIG. 3 . In addition, in the metal-resin composite material of FIG. 3 , the thicknesses of the two metal layers 10 and the two resin layers 20 are the same, respectively.

The metal resin composite material of FIG. 3 satisfies the relationship of Tma/Tra=Tmb/Trb, and since the metal layer 10 is located on the surface layer of the part a, it is molded by arranging the part a side on the surface to which the pressing force F is applied. all.

The molding method of the metal resin composite material is not particularly limited as long as it is a method capable of applying a pressing force F to a predetermined surface, and a method known in the art can be used. As an example of a shaping|molding method, a drawing process, a protrusion process, bending process, air pressure forming, etc. are mentioned. Among these, the drawing process with favorable workability with respect to a complicated shape is preferable. When the forming method is drawing processing, the pressing force F is applied by a punch.

Here, as an example, the method of applying the pressing force F in drawing is demonstrated using FIG. 4 . When the surface to which the pressing force F is applied is the a-side side of the metal resin composite material, the a-side side of the metal-resin composite material is disposed on the surface in contact with the punch 30 to which the pressing force F is applied. Then, by pressing and molding the punch 30 in the thickness direction of the metal resin composite material, a molded body (metal resin composite part) having a predetermined shape can be obtained. Although not shown, the metal resin composite material is placed on a die and the periphery is fixed with a blank holder, followed by molding with a punch 30 .

In addition, although shaping|molding of a metal resin composite material can be performed at room temperature or warm, even if it performs at room temperature, generation|occurrence|production of a springback can be suppressed.

The magnitude of the pressing force F may be appropriately adjusted according to the molding method to be used, the thickness of the metal-resin composite material, and the like, and is not particularly limited.

In the metal resin composite material, it is preferable that the metal layer 10 is disposed on the surface to which the pressing force F is applied. With such a configuration, when the electromagnetic wave shield housing is manufactured by molding the metal resin composite material, the inner surface of the electromagnetic wave shield housing becomes the metal layer 10, so that it is easy to ground.

It does not specifically limit as a material of the metal layer 10, Various metals can be used. Among them, from the viewpoint of enhancing the electromagnetic wave shielding effect with respect to an alternating magnetic field or an alternating electric field, a metal having excellent conductivity can be used. Specifically, the conductivity of the metal used for the metal layer 10 is preferably 1.0×10 ⁶ S/m (value at 20° C., the same hereinafter) or more, more preferably 10.0×10 ⁶ S/m or more. , more preferably 30.0×10 ⁶ S/m or more, and most preferably 50.0×10 ⁶ S/m or more. Examples of such conductive excellent metal, having a conductivity of about 9.9 × 10 ⁶ S / m of steel, having a conductivity of about 14.5 × 10 ⁶ S / m of nickel, the conductivity of about 39.6 × 10 ⁶ S / m aluminum, having a conductivity of about 58.0 Copper having a ×10 ⁶ S/m, and silver having an electrical conductivity of about 61.4 × 10 ⁶ S/m are exemplified. Among these, when both electrical conductivity and cost are considered, it is practically preferable to employ|adopt aluminum or copper. Moreover, you may use the above-mentioned metal alloy for the metal layer 10 .

In addition, when a plurality of metal layers 10 exist in the metal resin composite material, the plurality of metal layers 10 may be the same or different.

Various surface treatment layers may be formed on the surface of the metal layer 10 for the purpose of improving adhesion promoting properties, environmental resistance, heat resistance, rust prevention, and the like.

For example, for the purpose of improving the environmental resistance and heat resistance required when the metal surface is the outermost layer, Au plating layer, Ag plating layer, Sn plating layer, Ni plating layer, Zn plating layer, Sn on the surface of the metal layer 10 An alloy plating layer (Sn-Ag layer, Sn-Ni layer, Sn-Cu layer, etc.), a chromate-treated layer, etc. can be formed. These treatment layers can be single or multiple. Moreover, it is preferable to perform a Sn plating layer or a Sn alloy plating layer from a cost point among these process layers.

Moreover, for the purpose of improving the adhesiveness between the metal layer 10 and the resin layer 20, you may provide a chromate-treated layer, a roughening process layer, a Ni plating layer, etc. in the surface of the metal layer 10. These treatment layers can be used individually or in plurality. Moreover, since the effect of improving adhesiveness is high among these process layers, a roughening process layer is preferable.

In addition, for the purpose of enhancing the electromagnetic wave shielding effect with respect to the direct current magnetic field, a layer having high relative magnetic permeability may be provided on the surface of the metal layer 10 . Examples of the layer having high relative magnetic permeability include an Fe-Ni alloy plating layer, a Ni plating layer, and the like.

When using a copper foil layer as the metal layer 10, it is preferable from a viewpoint of improving an electromagnetic wave shielding effect that purity is high. The purity of the copper foil used for a copper foil layer becomes like this. Preferably it is 99.5 mass % or more, More preferably, it is 99.8 mass % or more.

As copper foil, although a rolled copper foil, an electrolytic copper foil, the copper foil by metallization, etc. can be used, The rolled copper foil excellent in a flexibility and moldability is preferable. When adding an alloying element to copper foil and setting it as copper alloy foil, total content of these elements and an unavoidable impurity should just be less than 0.5 mass %. In particular, when 200 to 2000 mass ppm of at least one selected from the group consisting of Sn, Mn, Cr, Zn, Zr, Mg, Ni, Si and Ag is contained in a total of 200 to 2000 mass ppm in copper foil, it is elongated than pure copper foil of the same thickness. This is preferable because it is improved.

The thickness of the metal layer 10 is not particularly limited, but per layer, 10 µm or more, preferably 15 µm or more, more preferably 20 µm or more, still more preferably 25 µm or more, particularly preferably 30 µm or more. . By making the thickness of the metal layer 10 into 10 micrometers or more, the electromagnetic wave shielding effect can fully be ensured. In addition, the thickness of the metal layer 10 per layer is preferably 100 µm or less, more preferably 50 µm or less, still more preferably 45 µm or less, and particularly preferably 40 µm or less. By making the thickness of the metal layer 10 into 100 micrometers or less, the fall of moldability can be suppressed.

When a plurality of metal layers 10 exist in the metal resin composite material, the thicknesses of the plurality of metal layers 10 may be the same or different.

It does not specifically limit as a material of the resin layer 20, Various resin can be used. Examples of the resin include PET (polyethylene terephthalate) resin, PEN (polyethylene naphthalate) resin, PI (polyimide) resin, PC (polycarbonate) resin, PE (polyethylene) resin, PP (polypropylene) resin, etc. can be heard Since all of these resins have relatively large springback, springback can be effectively suppressed when the molding method according to the present disclosure is applied using these resins. Moreover, among the resins mentioned above, cheap PET resin is preferable.

In addition, when a plurality of resin layers 20 exist in the metal resin composite material, the plurality of resin layers 20 may be the same or different.

Although the thickness of the resin layer 20 is not specifically limited, per layer, Preferably it is 10 micrometers or more, More preferably, it is 20 micrometers or more, More preferably, it is 30 micrometers or more, Especially more preferably, it is 40 micrometers or more. When the thickness of the resin layer 20 is 10 µm or more, when the housing is made of a metal resin composite material, the strength as a housing can be secured. Moreover, the thickness of the resin layer 20 per layer becomes like this. Preferably it is 300 micrometers or less, More preferably, it is 200 micrometers or less, More preferably, it is 150 micrometers or less. Moreover, when the thickness of the resin layer 20 shall be 300 micrometers or less, the fall of moldability can be suppressed.

When a plurality of resin layers 20 exist in the metal resin composite material, the thickness of the plurality of resin layers 20 may be the same or different, but the same is preferable.

Although the resin layer 20 can be formed using a resin film, you may form by apply|coating and hardening a resin material directly on the metal layer 10.

When using a resin film as the resin layer 20, it does not specifically limit as a bonding method of the metal layer 10 and a resin film, In the said technical field, a well-known method can be used. For example, the metal layer 10 and a resin film may be adhere|attached by thermocompression bonding, and the metal layer 10 and a resin film may be adhere|attached using an adhesive agent. However, since it is difficult to thermocompress a resin film, such as a PET resin film, with the metal layer 10, it is preferable to adhere|attach using an adhesive agent.

It does not specifically limit as an adhesive agent, Well-known adhesives, such as a thermoplastic adhesive agent and a thermosetting adhesive agent, can be used. Especially, since a thermosetting adhesive agent is chemically stable, it can make it difficult to generate|occur|produce the change with time of an adhesive part.

Here, the thermoplastic adhesive means an adhesive mainly containing a thermoplastic resin that softens when heated and hardens when cooled. Although it does not specifically limit as a thermoplastic resin, Polyvinyl acetate, a vinyl acetate-vinyl chloride copolymer, polyvinyl butyral, alpha-olefin resin, a cellulose resin, an acrylic resin, a vinyl chloride resin, polyvinyl acetal, etc. are mentioned. have. These can be used individually or in combination of 2 or more types.

In addition, a thermosetting adhesive means the adhesive agent which has as a main component the thermosetting resin which hardens when heated. Although it does not specifically limit as a thermosetting resin, A urea resin, a melamine resin, a phenol resin, a resorcinol resin, an epoxy resin, a structural acrylic resin, a polyester resin, a polyurethane resin, etc. are mentioned. These can be used individually or in combination of 2 or more types.

The total layer thickness of the metal resin composite material is not particularly limited, but is preferably 110 to 800 µm, more preferably 150 to 700 µm, still more preferably 200 to 600 µm, and particularly preferably 250 to 500 µm. . When the total layer thickness of the metal-resin composite material is 110 µm or more, when the housing is made of the metal-resin composite material, the strength as a housing can be secured. In addition, when the total layer thickness of the metal-resin composite material is 800 µm or less, a decrease in moldability can be suppressed.

The method for forming a metal-resin composite material according to an embodiment of the present invention can be used for a method for manufacturing a metal-resin composite part. Therefore, the manufacturing method of this metal-resin composite part includes the shaping|molding method of the metal-resin composite material which concerns on embodiment of this invention.

Here, in this specification, a "metal resin composite part" means a part obtained by shape|molding a metal resin composite material into a predetermined shape. Although it does not specifically limit as a metal resin composite component, Various components by which electromagnetic wave shielding characteristics are calculated|required are mentioned. Among them, the metal-resin composite component is preferably an electromagnetic wave shield housing.

The metal-resin composite part according to the embodiment of the present invention manufactured as described above has a laminated structure in which the metal layers 10 and 20 are alternately laminated, and the laminated structure is asymmetrical. is formed

In addition, the metal resin composite component according to the embodiment of the present invention is divided into parts a and b at a position half of the total layer thickness of the metal resin composite material, and the total layer thickness of the resin layer 20 present in the a part Tra, the total layer thickness of the metal layer 10 present in the a part, Tma, the total layer thickness of the resin layer 20 present in the b part, Trb, and the total layer thickness of the metal layer 10 present in the b part In the case where is Tmb, it has the structure of any one of the following (1) to (3).

(1) In the case of Tma/Tra>Tmb/Trb, the negative side a is disposed on the surface to which the pressing force F is applied.

(2) In the case of Tma/Tra<Tmb/Trb, the b negative side is disposed on the surface to which the pressing force F is applied.

(3) In the case of Tma/Tra=Tmb/Trb, on the surface to which the pressing force F is applied, the side where the metal layer 10 is located on the surface layer or the side close to the metal layer 10 among the a or b portions is disposed.

By setting it as the above structure, since generation|occurrence|production of a springback at the time of shaping|molding of a metal-resin composite material can be suppressed, the dimensional accuracy of a metal-resin composite part can be improved.

In addition, since it is as above-mentioned about the detail of the metal-resin composite material which forms a metal-resin composite component, description is abbreviate|omitted.

[Example]

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited by these Examples at all.

<Production of metal resin composite material A>

A metal resin composite material A having a two-layer structure by laminating a rolled copper foil (thickness 17 µm) and a PET resin film (thickness 100 µm) formed on the surface with a roughening layer formed on the surface (hereinafter, this laminated structure is reduced to "Cu/PET") in some cases) was produced. In addition, the thermosetting adhesive agent was used for adhesion|attachment of rolled copper foil and PET resin film. In addition, in this metal resin composite material A, the rolled copper foil side is called a part side, and the PET resin film side is called the b part side.

<Production of metal resin composite material B>

A metal resin composite material B having a two-layer structure by laminating a rolled copper foil (thickness 18 μm) and a PET resin film (thickness 100 μm) formed with a roughening treatment layer on the surface (hereinafter, this laminated structure is reduced to “Cu/PET”) in some cases) was produced. In addition, the thermosetting adhesive agent was used for adhesion|attachment of rolled copper foil and PET resin film. In addition, in this metal resin composite material B, the rolled copper foil side is called a part side, and the PET resin film side is called a part b side.

<Production of metal resin composite material C>

A metal resin composite material C having a two-layer structure by laminating a rolled copper foil (thickness 35 μm) and a PET resin film (thickness (100 μm) with a roughening treatment layer formed on the surface (hereinafter referred to as “Cu/PET”) In addition, a thermosetting adhesive was used for bonding the rolled copper foil and the PET resin film.In this metal resin composite material C, the rolled copper foil side is the a side, the PET resin film side. is called subside b.

<Production of metal resin composite material D>

Three rolled copper foils (thickness 18 µm) and three PET resin films (thickness 100 µm) having a roughening treatment layer formed on the surface are alternately laminated to form a metal resin composite material D having a six-layer structure (hereinafter, this laminate structure is referred to as “ Cu/PET/Cu/PET/Cu/PET") was produced. In addition, the thermosetting adhesive agent was used for adhesion|attachment of rolled copper foil and PET resin film. In addition, in this metal resin composite material D, the rolled copper foil side exposed to the surface layer is called a part side, and the PET resin film side exposed to the surface layer is called part b side.

<Production of metal resin composite material E>

Three rolled copper foils (thickness of 18 µm) and three PET resin films (thickness of 50 µm) having a roughening treatment layer formed on the surface are alternately laminated to form a metal resin composite material E having a six-layer structure (hereinafter, this laminate structure is referred to as “ Cu/PET/Cu/PET/Cu/PET") was produced. In addition, the thermosetting adhesive agent was used for adhesion|attachment of rolled copper foil and PET resin film. In addition, in this metal resin composite material E, the side of the rolled copper foil exposed to the surface layer is called a part side, and the PET resin film side exposed to the surface layer is called part b side.

<Production of metal resin composite material F>

Two rolled copper foils (thickness 35 µm) and two PET resin films (thickness 50 µm) having a roughening treatment layer formed on the surface are alternately laminated to form a metal resin composite material F having a four-layer structure (hereinafter, this laminate structure is referred to as “ Cu/PET/Cu/PET") was produced. In addition, the thermosetting adhesive agent was used for adhesion|attachment of rolled copper foil and PET resin film. In addition, in this metal resin composite material F, the rolled copper foil side exposed to the surface layer is called a part side, and the PET resin film side exposed to the surface layer is called part b side.

Table 1 shows the values of Tma/Tra and Tmb/Trb calculated from the laminate structures of the metal resin composite materials A to F produced as described above.

In addition, the following evaluation was performed using the above-described metal resin composite materials A to F.

<Forming processability>

Using the above-described metal-resin composite materials A to F, drawing was performed on a square cylinder having a flange portion of 90°. In the drawing process, with respect to each of the metal resin composite materials A to F, the a-part side and the b-part side were arranged on the surface to which the pressing force by the punch was applied, and performed twice each.

In this evaluation, in the case of comparing the results of molding processability by a molding method using a metal resin composite material of the same type, a molding method in which the springback of the flange portion is small is denoted by ○, and a molding method in which the flange portion is large is denoted by ×. For example, as shown in FIG. 5, in the metal resin composite material A, the molded article (metal resin composite part) of Example 1 molded by arranging the a side on the surface to which the pressing force by the punch is applied is the , compared with the molded article of Comparative Example 1 molded by arranging the side b on the surface to which the pressing force is applied, the springback of the flange portion was clearly reduced. Therefore, the processing moldability of the molded article of Example 1 was evaluated by (circle), and the processing moldability of the molded article of the comparative example 1 was evaluated as x, respectively.

<W bending test>

A test piece having a width of 10 mm and a length of 60 mm was cut out from the metal resin composite materials A to F described above. This test piece was subjected to 90°W bending at room temperature at a processing speed of 900 mm/min, a bending radius of 0 mm, a load of 2 kN, and a holding time of 2 seconds at the bottom dead center. In the bending portion (central portion), which is the peak of the test piece subjected to W bending, the angle of the bending portion was measured, and the deviation from 90° (90°-measurement angle), that is, the magnitude of the springback was determined.

Table 1 shows each evaluation result described above.

As shown in Table 1, the metal resin composite material A was Tma/Tra>Tmb/Trb. For this reason, compared to the case where the part b side was arranged on the pressing force application surface and molded (Comparative Example 1), the case where the a part side was arranged on the pressing force application surface and molded (Example 1) was higher in molding processability and W The result of the bending test was favorable.

Since the metal resin composite material B was Tma/Tra>Tmb/Trb, it was molded by arranging the a-side side on the pressing force imparting surface compared to the case where the b-side side was disposed on the pressing force application surface (Comparative Example 2) In the case (Example 2), the moldability and the results of the W bending test were better.

Since the metal resin composite material C was Tma/Tra>Tmb/Trb, it was molded by arranging the a-side side on the pressing force imparting surface compared to the case of molding by arranging the b-side side on the pressing force imparting surface (Comparative Example 3). In the case (Example 3), the moldability and the results of the W bending test were better.

Since the metal resin composite material D was Tma/Tra>Tmb/Trb, it was molded by arranging the a-side side on the pressing force imparting surface compared to the case where the b-side side was arranged on the pressing force application surface (Comparative Example 4) In the case (Example 4), the moldability and the results of the W bending test were better.

Since the metal resin composite material E was Tma/Tra>Tmb/Trb, it was molded by arranging the a-side side on the pressing force imparting surface compared to the case where the b-side side was arranged on the pressing force imparting surface and molded (Comparative Example 5). In the case (Example 5), the moldability and the results of the W bending test were better.

The metal resin composite material E was Tma/Tra=Tmb/Trb, and it was the a side that the metal layer was located in the surface layer. Therefore, compared to the case where the b-side side was arranged and molded on the pressing force imparting surface (Comparative Example 6), the case where the a-part side was arranged on the pressing force applying surface and molded (Example 6) was higher in molding processability and W The result of the bending test was favorable.

As can be seen from the above results, according to the embodiment of the present invention, it is possible to provide a method for molding a metal-resin composite material capable of suppressing springback. Moreover, according to embodiment of this invention, a metal-resin composite part with high dimensional accuracy, and its manufacturing method can be provided.

10: metal layer
20: resin layer
30: punch

Claims (17)

A method for molding a metal-resin composite material having a laminated structure in which metal layers and resin layers are alternately laminated, wherein the laminated structure is asymmetrical,
The total layer thickness of the resin layers present in the a part is divided into parts a and b at a position half of the total layer thickness of the metal resin composite material, Tra, the total layer thickness of the metal layers present in the a part. Tma, the total layer thickness of the resin layer present in the b part is Trb, and the total layer thickness of the metal layer present in the b part is Tmb,
When Tma/Tra>Tmb/Trb, molding is performed by arranging the a-part side on the surface to which the pressing force is applied,
When Tma/Tra<Tmb/Trb, molding is performed by arranging the b-side side on a surface to which a pressing force is applied,
In the case of Tma / Tra = Tmb / Trb, on the surface to which the pressing force is applied, the side where the metal layer is located on the surface layer or the side close to the metal layer is arranged on the surface of the a part or the b part to perform molding, a metal resin composite The molding method of the material. The method for molding a metal-resin composite material according to claim 1, wherein the molding is performed by drawing processing. The method for molding a metal resin composite material according to claim 1 or 2, wherein the metal layer is a copper foil layer. The method for molding a metal resin composite material according to claim 1 or 2, wherein the resin layer is a PET resin layer. The method for molding a metal resin composite material according to claim 1 or 2, wherein the thickness of one of the metal layers is 10 to 50 µm. The method for molding a metal resin composite material according to claim 1 or 2, wherein the thickness of one of the resin layers is 20 to 200 µm. The method for molding a metal-resin composite material according to claim 1 or 2, wherein the metal layer is disposed on the surface to which the pressing force is applied. The method for molding a metal-resin composite material according to claim 1 or 2, wherein the metal layer and the resin layer are adhered to each other with an adhesive. A method for manufacturing a metal resin composite part comprising the method for molding the metal resin composite material according to claim 1 or 2 . A metal resin composite part having a laminated structure in which metal layers and resin layers are alternately laminated, and the laminated structure is formed of a metal resin composite material asymmetrical;
The total layer thickness of the resin layers present in the a part is divided into parts a and b at a position half of the total layer thickness of the metal resin composite material, Tra, the total layer thickness of the metal layers present in the a part. Tma, the total layer thickness of the resin layer present in the b part is Trb, and the total layer thickness of the metal layer present in the b part is Tmb,
When Tma/Tra>Tmb/Trb, the side a is disposed on the surface to which the pressing force is applied,
When Tma/Tra<Tmb/Trb, the side b is disposed on the surface to which the pressing force is applied,
In the case of Tma/Tra=Tmb/Trb, a side where the metal layer is positioned on the surface layer or a side close to the metal layer among the a or b parts is disposed on the surface to which the pressing force is applied. The metal-resin composite part according to claim 10, wherein the metal layer is a copper foil layer. The metal-resin composite part according to claim 10 or 11, wherein the resin layer is a PET resin layer. The metal-resin composite part according to claim 10 or 11, wherein the thickness of one of the metal layers is 10 to 50 µm. The metal-resin composite part according to claim 10 or 11, wherein the thickness of one of the resin layers is 20 to 200 µm. The metal-resin composite component according to claim 10 or 11, wherein the metal layer is disposed on the surface to which the pressing force is applied. The metal-resin composite part according to claim 10 or 11, wherein the metal layer and the resin layer are adhered with an adhesive. The metal-resin composite component according to claim 10 or 11, which is an electromagnetic wave shield housing.

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