TW201531399A - 複合構件、及複合構件的製造方法 - Google Patents

複合構件、及複合構件的製造方法 Download PDF

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Publication number
TW201531399A
TW201531399A TW104102680A TW104102680A TW201531399A TW 201531399 A TW201531399 A TW 201531399A TW 104102680 A TW104102680 A TW 104102680A TW 104102680 A TW104102680 A TW 104102680A TW 201531399 A TW201531399 A TW 201531399A
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TW
Taiwan
Prior art keywords
resin
metal plate
composite member
opening
curved
Prior art date
Application number
TW104102680A
Other languages
English (en)
Inventor
Taisuke Tsubota
Ryuichi Inoue
Masatada Numano
Osamu Mizuno
Motoyoshi Tanaka
Nozomu Kawabe
Katsuyuki Aoki
Original Assignee
Sumitomo Electric Industries
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Filing date
Publication date
Application filed by Sumitomo Electric Industries filed Critical Sumitomo Electric Industries
Publication of TW201531399A publication Critical patent/TW201531399A/zh

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    • B21D11/08—Bending by altering the thickness of part of the cross-section of the work
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Abstract

一種複合構件，具備：具有由彎曲加工所形成之彎曲部的金屬板、及接合於前述彎曲部之至少一部分的樹脂構件，前述金屬板具有：形成於前述彎曲部之內側的開口部；及從前述彎曲部的外側朝向前述開口部形成前端尖細之錐狀的凹部，前述樹脂構件具有：被充填於前述凹部內的內側樹脂部；及與前述內側樹脂部連接，且形成經過前述開口部的緣部而到達前述彎曲部之內面的露出樹脂部。

Description

複合構件、及複合構件的製造方法
本發明有關可適合運用於可攜式電氣機器的框體等的複合構件及其複合構件的製造方法。
可攜式電氣機器的框體一般是按照其使用狀態去安裝各種的後裝式零件(例如，安裝有IC晶片的基板或監視器等)，在框體為以金屬構件所構成的情況下，期望具有後裝式零件的安裝部。專利文獻1中所揭示於鎂合金的壓延板的緣部，具備樹脂構件作為安裝部的鎂合金構件。具體而言，該鎂合金構件是藉著以於鎂合金的壓延板形成貫穿孔，而填埋此貫穿孔內面的方式接合樹脂構件，並且其樹脂構件到達壓延板其中一方的面和另一方的面，而讓樹脂構件牢固地接合於壓延板。此鎂合金構件是例如藉由於壓延板衝裁形成貫穿孔，且將形成此貫穿孔的壓延板配置於模具後，將樹脂嵌件成型於模具內進行製造。
[先前技術文獻] [專利文獻]
[專利文獻1]日本特開2010-69699號公報
在上述專利文獻1的技術中，因為樹脂構件被固定成從形成於壓延板的貫穿孔的內周面形成至壓延板的兩面，所以於壓延板的兩面形成樹脂構件的凸起。依照框體的使用狀態，會希望僅於壓延板(金屬板)其中一面具備樹脂構件的形態。例如，在安裝零件於框體內部的情況下，不須在框體的外側形成樹脂構件。因此，期望在不將樹脂構件形成至金屬板的外側面的情形下，可以將金屬板和樹脂構件強固地接合的複合構件。
本發明有鑑於上述事情而發明，且本發明的目的其中之一是提供金屬板和樹脂構件強固地接合的複合構件。另外，本發明的另一個目的在於提供有效率地製得將金屬板和樹脂構件強固地接合的複合構件之複合構件的製造方法。
本發明的複合構件具備：具有由彎曲加工所形成之彎曲部的金屬板、及接合於前述彎曲部之至少一部分的樹脂構件。前述金屬板具有：形成於前述彎曲部之內側的開口部；及從前述彎曲部的外側朝向前述開口部形成 前端尖細之錐狀的凹部。前述樹脂構件具有：被充填於前述凹部內的內側樹脂部；及與前述內側樹脂部連接，且形成經過前述開口部的緣部而到達前述彎曲部之內面的露出樹脂部。
本發明的複合構件的製造方法具備以下步驟。
(A)準備步驟，用來準備平板狀的金屬板。
(B)凹部形成步驟，在前述金屬板實施彎曲加工之部位的至少一部分，形成具有開口部的凹部。
(C)彎曲步驟，將前述開口部作為彎曲的內側，而對前述金屬板實施彎曲加工。
(D)樹脂充填步驟，對前述凹部內充填樹脂，並使樹脂成形為經過前述開口部的緣部而到達前述金屬板之彎曲的內面。
本發明的複合構件是金屬板和樹脂構件強固地接合。
本發明的複合構件的製造方法可有效率地製得金屬板和樹脂構件強固地接合的複合構件。
1、2、3、4‧‧‧複合構件
20‧‧‧金屬板
21‧‧‧彎曲部
22‧‧‧開口部
22i‧‧‧內側開口部
22o‧‧‧外側開口部
23‧‧‧凹部
23a‧‧‧貫穿孔
23b‧‧‧溝
24‧‧‧嵌合凹部
30‧‧‧樹脂構件
31‧‧‧內側樹脂部
32‧‧‧露出樹脂部
32L‧‧‧L形片
32p‧‧‧間隔片
100‧‧‧後裝式零件
ms‧‧‧公螺絲部
fs‧‧‧母螺絲部
t‧‧‧錐部
c‧‧‧嵌合部
P‧‧‧衝頭
第1圖是將製造實施方式1之複合構件的方法加以示 意性說明的步驟說明圖。
第2圖是例示實施方式1之複合構件和後裝式零件的卡合狀態的的概略圖。
第3圖是例示實施方式1之複合構件和後裝式零件的卡合狀態的的概略圖。
第4圖是例示實施方式1之複合構件中之樹脂構件的配置形態的概略圖。
第5圖是例示實施方式1之複合構件中之樹脂構件的配置形態的概略圖。
第6圖是表示實施方式2之複合構件的剖面圖。
第7圖是例示實施方式3之複合構件中之樹脂構件的配置形態的概略圖。
第8圖是表示實施方式4之複合構件的剖面圖。
[本發明的實施方式之說明]
本發明者想到在將金屬板和樹脂構件接合時，設置從金屬板其中一方的面(框體之外側的面)朝向另一方的面(框體之內側的面)形成前端尖細之錐狀的凹部，藉由此錐狀的凹部構成樹脂構件的防脫落構造。藉著以形成於錐形的前端尖細部分的開口部為邊界，經過凹部內和開口部的緣部到達框體之內側的面來設置樹脂構件，可以將樹脂構件卡止在從錐形面連接至框體之內側的面的區域。錐狀 的凹部的形成可舉出如下述順序的方法：準備平板狀的金屬板→對金屬板實施彎曲加工而將框體成形→在框體的平坦部分從框體的內面朝向外面形成筆直的凹部→對於凹部形成錐形。此錐形的形成是藉由例如與筆直的凹部之形成不同的切削步驟來進行。
本發明者們進一步檢討有效率地形成錐狀的凹部的方法。其結果，發現藉著將凹部形成在框體的角部(由彎曲加工所形成之彎曲部分)，可以減少製造步驟。具體而言，想到以下述順序進行方法：準備平板狀的金屬板→在金屬板的平坦部分形成筆直的凹部→將凹部的開口部作為彎曲的內側而實施彎曲加工且將框體成形。將筆直的凹部加以彎曲時，因為沿著彎曲從彎曲的外側朝向內側形成前端尖細之錐狀的凹部，所以得到可以省略以切削工具等對於凹部形成錐形的步驟之見解進而完成本發明。以下，列舉本發明的實施方式的內容進行說明。
(1)實施方式之複合構件具備：具有由彎曲加工所形成之彎曲部的金屬板、及接合於前述彎曲部之至少一部分的樹脂構件。前述金屬板具有：形成於前述彎曲部之內側的開口部；及從前述彎曲部的外側朝向前述開口部形成前端尖細之錐狀的凹部。前述樹脂構件具有：被充填於前述凹部內的內側樹脂部；及與前述內側樹脂部連接，且形成經過前述開口部的緣部而到達前述彎曲部之內面的露出樹脂部。
藉由上述實施方式之複合構件，形成於金屬 板之彎曲部的錐狀的凹部成為樹脂構件的防脫落構造，即使是僅在金屬板的其中一面(複合構件(框體)的內側的面)設置樹脂構件的情況下，亦可以將金屬板和樹脂構件強固地接合。其原因為凹部的開口部形成前端尖細部分，藉著從此前端尖細面經過開口部的緣部到達彎曲部的內面接合樹脂構件，內側樹脂部及露出樹脂部卡在從錐形面連接至彎曲部之內側的面的區域。因而，內側樹脂部及露出樹脂部是以開口部為邊界，即使對彎曲的內外的任一側施加力道，因為在上述區域卡住，所以樹脂構件不易從金屬板脫落。
(2)以實施方式之複合構件而言，例如有前述凹部為貫穿孔。
藉著凹部為貫穿孔，從外側觀看複合構件的時候，可以具有金屬和樹脂雙方的質感。藉著對樹脂實施具有金屬質感的塗裝，亦可讓金屬板和樹脂構件彷彿成為相同材質般的設計。藉著改變樹脂的顏色或在樹脂上施加裝飾，提高設計性。另外，藉著藉由貫穿孔部分地去掉金屬，可以利用貫穿孔的部位作為電磁波的傳播點。例如，在金屬板的內側中之貫穿孔的附近配置天線的話，金屬板不會遮蔽天線所收送訊的電磁波。
(3)以實施方式之複合構件而言，例如有前述凹部為溝。
藉著凹部為溝，因為在複合構件的外側不存在孔洞，所以從外側觀看複合構件的時候，可以在外側整 體上具有金屬質感。
(4)以實施方式之複合構件而言，例如有前述金屬板具備可供前述露出樹脂部充填的嵌合凹部。
藉著露出樹脂部被充填於嵌合凹部，因為金屬板和露出樹脂部的接合面積變大而且卡在金屬板，所以樹脂構件更不易從金屬板脫落。另外，在複合構件的內面，可以將露出樹脂部和金屬板的內面成為相同平面，且可以擴大內部空間。
(5)以實施方式之複合構件而言，例如有前述複合構件為電氣機器的框體。
因為本實施方式之複合構件是金屬板和樹脂構件強固地接合，所以可以適合運用於如可攜裝置或電腦的框體等，期望能安裝各種後裝式零件的電氣機器的框體。
(6)實施方式之複合構件的製造方法具備以下步驟。
(A)準備步驟，用來準備平板狀的金屬板。
(B)凹部形成步驟，在前述金屬板實施彎曲加工之部位的至少一部分，形成具有開口部的凹部。
(C)彎曲步驟，將前述開口部作為彎曲的內側，而對前述金屬板實施彎曲加工。
(D)樹脂充填步驟，對前述凹部內充填樹脂，並使樹脂成形為經過前述開口部的緣部而到達前述金屬板之彎曲的內面。
藉由上述實施方式之複合構件的製造方法，由於可以利用彎曲加工於凹部形成錐形，因而可以有效率地製造複合構件。用來在凹部形成錐形，一般是認為形成筆直的凹部，且在其凹部以鑽頭等形成錐形。在本實施方式之製造方法中，於在平板狀的金屬板形成筆直的凹部，且對金屬板實施彎曲加工而將框體成形時，藉著以凹部的開口部作為彎曲的內側，可以容易在凹部形成錐形。將筆直的凹部加以彎曲時，因為在沿著彎曲從彎曲的外側朝向內側形成前端尖細之錐狀的凹部發生塑性變形，所以可以省略以切削工具等對於凹部形成錐形的步驟，且可以提昇生產率。特別是，在沿著藉由彎曲所形成之角部的稜線方向而形成複數個錐狀的凹部時，本實施方式之複合構件的製造方法相當有效果。
(7)以實施方式之複合構件的製造方法而言，例如前述準備步驟具備將素材板衝裁成特定形狀而形成前述平板狀金屬板的衝裁步驟，且與前述衝裁步驟同時執行前述凹部形成步驟，而穿孔形成貫穿前述素材板兩面的貫穿孔，進而形成凹部。
在凹部為貫穿孔的情況下，藉著與衝裁素材板的衝裁步驟同時將貫穿孔加以穿孔，可以有效率地形成錐狀的貫穿孔(凹部)。特別是在形成複數個錐狀的貫穿孔時，可以將複數個貫穿孔同時穿孔，藉著將此些貫穿孔其中一方的開口部作為彎曲的內側而實施彎曲加工，由於可以在複數個貫穿孔形成錐形，因而可以有效率地形成錐 狀的貫穿孔。
(8)作為實施方式之複合構件，提案藉由上述(6)或(7)的實施方式之複合構件的製造方法所製造。
實施方式之複合構件是形成於金屬板之彎曲部的錐狀的凹部成為樹脂構件的防脫落構造，且可以將金屬板和樹脂構件強固地接合。另外，因為於金屬板形成筆直的凹部，且利用從金屬板成形框體時的彎曲加工於凹部形成錐形，所以可以有效率地製造複合構件，生產率優異。
[本發明的實施方式之詳細]
將本發明的實施方式之詳細，在以下進行說明。此外，本發明並非受限於此些例示，其主旨包含藉由專利申請之範圍所示，且與專利申請之範圍同等的意義及在範圍內的所有變更。在圖式中，相同符號表示相同名稱物品。
<實施方式1> 《複合構件》
本實施方式之複合構件1，如第1圖的下圖所示般，金屬板20和樹脂構件30在金屬板20的施加彎曲加工的彎曲部21的部位進行接合。
[金屬板]
金屬板的材質例如可列舉如純鎂、鎂合金、純鈦、鈦合金、純鋁、鋁合金、純鐵、及鐵合金(包含鋼、不銹鋼)。此些金屬皆滿足楊氏模數：40GPa以上、0.2%耐力：150MPa以上、熱膨脹率：8×10-6/K以上，而且剛性高，凹陷或反翹等的變形不易發生，容易長期間維持形狀。
特別是，金屬板之至少一部分是由純鎂、鎂合金、純鈦、及鈦合金之至少一種所構成的形態時，由於此些金屬的強度或剛性優良，因而容易將金屬板薄型化。另外，純鎂、鎂合金、純鈦、及鈦合金由於分量比鐵或鐵合金輕，因而容易將複合構件輕量化。
尤其鎂或鎂合金因為比強度、比剛性高，所以容易作為高強度且高剛性的複合構件。鎂是由Mg及不可避免之不純物所構成者，鎂合金例如是在合計為0.01質量%以上20質量%以下含有由Al、Zn、Mn、Si、Be、Ca、Sr、Y、Cu、Ag、Sn、Li、Zr、Ce、Ni、Au及稀土類元素(Y，Ce除外)選出之1種以上的元素，而且其剩餘部分為由Mg及不可避不純物所構成者。特別是，含有Al的鎂合金不但耐蝕性優良而且強度等之機械特性亦優異而較為合適。Mg-Al系合金之更具體的組成，例如可列舉ASTM規格中之AZ系合金(Mg-Al-Zn系合金、Zn：0.2質量%~1.5質量%)、AM系合金(Mg-Al-Mn系合金、Mn：0.05質量%~0.5質量%)、AS系合金(Mg-Al-Si系合金、Si：0.3質量%~4.0質量%)、Mg-Al-RE(稀 土類元素)系合金、AX系合金(Mg-Al-Ca系合金、Ca：0.2質量%~6.0質量%)、AZX系合金(Mg-Al-Zn-Ca系合金、Zn：0.2質量%~1.5質量%、Ca：0.1質量%~4.0質量%)、AJ系合金(Mg-Al-Sr系合金、Sr：0.2質量%~7.0質量%)等。Al的含有量較佳為3質量%以上，5.5質量%甚至7.3質量%以上更佳。但是，當Al的含有量超過12質量%時由於會招致塑性加工性的降低，因而將上限定為12質量%。Al的含有量為11質量%以下，而且較佳為10.5質量%以下，特別是較佳為8.3質量%~9.5質量%。
金屬板之至少一部分可以是由純鋁、鋁合金、純鐵、及鐵合金選出之至少一種的金屬所構成的形態。純鋁、鋁合金、鐵、及鐵合金，一般因為壓延或沖壓等之塑性加工的加工性優異，所以可以容易形成所希望的形狀之塑性加工材。純鋁、鋁合金由於分量輕，因而可以藉著具備由純鋁或鋁合金所構成的金屬板而形成輕量的複合構件。純鋁是由Al及不可避不純物所構成者，鋁合金可以利用例如JIS H 4000(2006)等所規定之各種的合金：A1050、A5052、A5083等。純鐵或鐵合金一般由於強度優異，因而藉著具備由純鐵或鐵合金構成的金屬板可以形成高強度的複合構件。純鐵是由Fe及不可避不純物所構成者，鐵合金可以利用例如碳和鐵的合金也就是鋼，甚至包含Ni或Cr的不銹鋼，例如SUS304或SUS316等。
金屬板20具有由彎曲加工所形成之彎曲部 21，可列舉例如剖面ㄈ狀、剖面L狀等的形狀。在複合構件為電氣機器的框體的情況下，可列舉由底板部及從此底板部豎立設置的側壁部所構成的有底箱狀，連接底板部和側壁部的角部是藉由彎曲加工所形成的彎曲部。彎曲部不但有連接底板部和側壁部的兩面的角部的情況，也有連接底板部和兩個側壁部的合計三面的角部的情況。
在彎曲部21形成具有開口部22的凹部23。在本實施方式中，凹部23是分別在彎曲部21的內側及外側的雙方具有內側開口部22i及外側開口部22o的貫穿孔23a。此貫穿孔23a形成從外側開口部22o朝向內側開口部22i成為前端尖細之錐狀。換言之即內側開口部22i的大小比外側開口部22o的大小更小的剖面扇形。
貫穿孔23a的錐形的延長線上的交點中之角度θ(第1圖的下圖)，例如可為60度以上且150度以下。藉著上述角度θ為60度以上，在對貫穿孔23a充填樹脂，並且以到達彎曲部21的內面的方式形成樹脂構件30的時候，可以讓充填於貫穿孔23a的樹脂不易從金屬板20脫落。此角度θ更佳為90度以上。當上述角度θ為90度時，適合將複合構件1作為框體使用。因為上述角度θ越大彎曲部21的彎曲加工就變得越大，所以較佳為135度以下，更佳為120度以下。
金屬板20可列舉如厚度為0.5mm以上且5.0mm以下之任意的形狀者。藉著厚度為0.5mm以上，因為貫穿孔23a的錐形面和樹脂構件30的接合面積變大 所以可以讓樹脂構件30不易從金屬板20脫落。因為厚度越厚越能提高複合構件1的強度或剛性，所以更佳為1.0mm以上。因為厚度越厚複合構件1變得越大，所以更佳為3.0mm以下。
金屬板可以經由鑄造、押出、壓延、鍛造、沖壓(代表性的有彎曲加工或旋壓成型)等種種步驟製造。製造上可以適當利用眾所周知的製造條件。所製得之金屬板，可列舉如鑄造材；押出材；壓延材；鍛造材；沖壓材；其他塑性加工材；以此些作為素材進一步實施熱處理、研磨、矯正、切削、防蝕處理、表面加工中至少一種處理的處理材等種種形態。在金屬板為鑄造材的情況下，可以容易形成任意的立體形狀。以鑄造材等作為素材，而對此素材實施押出、壓延、鍛造、及沖壓等之塑性加工的金屬板藉由加工硬化，強度或剛性更高。實施研磨、矯正、表面加工等的金屬板，設計性優異。實施防蝕處理的金屬板，耐蝕性優良。另外，藉著實施熱處理進行組成的均質化或去除塑性加工所造成之應力等，而藉由切削獲得特定的大小或厚度的金屬板。可將金屬板適當製造成所希望的形狀、形態而加以利用。
[樹脂構件]
樹脂構件30具有：被充填於金屬板20之貫穿孔23a內的內側樹脂部31；及與該內側樹脂部31連接，且形成經過內側開口部22i的緣部而到達彎曲部21之內面的露 出樹脂部32。在此，樹脂構件30未到達彎曲部21的外面，樹脂構件30(內側樹脂部31)的外面與金屬板20的外面成為相同平面。樹脂構件30亦可進一步與內側樹脂部31連接，且形成經過外側開口部22o的緣部而到達彎曲部21之外面(未圖示)。
露出樹脂部32是例如在彎曲部21的內面，從貫穿孔23a(內側開口部22i)的中心軸至少對向而往兩個方向形成。例如，在複合構件具有底板部和側壁部的框體的情況下，形成於底板部及側壁部。例如露出樹脂部32是設置成從貫穿孔23a的內側開口部22i的緣部沿著彎曲部21的內面到達的長度(示於第1圖的下圖的長度m)，是從貫穿孔23a的中心軸至內側開口部22i的緣部為止的長度(示於第1圖的中間圖的長度n)的0.8倍以上。藉著將露出樹脂部32以上述0.8倍以上形成，可以使露出樹脂部32和金屬板20的接合面積擴大，且可以使樹脂構件30不易從金屬板20脫落。具體而言，藉著貫穿孔23a為錐狀，內側樹脂部31不易穿透至彎曲部21的內側，藉著露出樹脂部32從內側開口部22i的緣部到達彎曲部21的內面的廣範圍，露出樹脂部32不易穿透至彎曲部21的外側。長度m較佳為長度n的0.9倍以上，更佳為2倍以上。特別是，長度m較佳為與從貫穿孔23a的中心軸至外側開口部22o的緣部為止的長度(示於第1圖的中間圖的長度k)同等以上。因此可以讓樹脂構件30不易從金屬板20脫落。
另外，藉著讓從貫穿孔23a的緣部沿著彎曲部21的內面到達的長度m在貫穿孔23a的周方向上均等，容易定位與後述之後裝式零件的卡合部的形成位置。其他，亦可露出樹脂部32是從內側開口部22i的緣部形成放射狀。
露出樹脂部32可列舉如厚度為沿著金屬板20的內面實質上均一的板狀物。其他，可舉出部分厚度不同者，例如具有突出部。露出樹脂部32例如上述板狀部分之金屬板20的厚度方向的厚度為0.5mm以上且5.0mm以下。藉著厚度為0.5mm以上，容易形成與後述之後裝式零件100的接合部，藉著擴大其接合面積，可以讓複合構件1和後裝式零件100不易脫落。因為厚度越厚越容易在露出樹脂部32形成上述接合部，所以更佳為1.0mm以上。因為厚度越厚露出樹脂部32變得越大，所以更佳為3.0mm以下。
樹脂構件30的材料只須考慮材質的硬度或耐蝕性、耐久性、耐熱性等，按照複合構件1的用途適當選擇即可，沒有特別限定。例如，熱可塑性樹脂或熱硬化性樹脂，以具體例而言，可以列舉如聚丙烯樹脂、或聚乙烯樹脂、聚苯乙烯樹脂、聚氯乙烯樹脂、聚對苯二甲酸乙二酯樹脂、聚對苯二甲酸丁二酯樹脂、聚碳酸酯樹脂、丙烯酸樹脂、環氧樹脂、酚醛樹脂、矽氧樹脂等。另外，作為樹脂構件30的材料，橡膠材料具體而言可以列舉如天然橡膠、或異戊二烯橡膠或苯乙烯橡膠、腈橡膠、氫丁二烯橡膠、丙烯酸橡膠、矽氧橡膠、胺基甲酸酯橡膠等的合成 橡膠等。亦可在由此些材料構成的樹脂構件摻合填充劑或色母料等。
[金屬板和樹脂構件的接合]
金屬板20和樹脂構件30是如第1圖的下圖所示般，藉著在形成於金屬板20的錐狀的凹部23(貫穿孔23a)充填內側樹脂部31，而與該內側樹脂部31連接且形成露出樹脂部32的方式進行接合。露出樹脂部32是藉著形成經過內側開口部22i的緣部而到達彎曲部21的內面，讓內側樹脂部31及露出樹脂部32卡在從錐形面的前端尖細面連接至彎曲部21的內側的面的區域。因而，上述錐狀的凹部23成為防脫落構造，讓金屬板20和樹脂構件30強固地接合。
《複合構件的製造方法》
本實施方式之複合構件的製造方法具備以下的準備步驟、凹部形成步驟、彎曲步驟、樹脂充填步驟。以下，依據第1圖，將各步驟依序進行說明。
[準備步驟(衝裁步驟)]
首先，準備平板狀的金屬板。此平板狀的金屬板，可以藉由將上述金屬板的材質的素材板衝裁成矩形等之特定的形狀而成為平板狀的衝裁步驟加以製得。或者，亦可使用衝裁成特定的形狀後的金屬板。在將素材板衝裁而形成 平板狀的金屬板的情況下，此素材板可以經由鑄造、押出、壓延、鍛造等種種步驟製造。
[凹部形成步驟]
接著，如第1圖的上圖所示般，在平板狀的金屬板20以衝頭P等形成凹部23。在此，分別於金屬板20的兩面穿孔出具有開口部22(內側開口部22i及外側開口部22o)的貫穿孔23a而形成凹部23。貫穿孔23a是在後述彎曲步驟形成實施彎曲加工部位之至少一部分。有關貫穿孔23a的形成部位，將在之後的複合構件和後裝式零件的卡合的說明時進行詳述。
貫穿孔23a可列舉開口部22為圓形或矩形、橢圓形等種種的形狀。貫穿孔23a的開口部22的大小，只要是在對貫穿孔23a充填樹脂，並且以到達金屬板20之彎曲部21的內面的方式形成樹脂構件30的時候，充填於貫穿孔23a的樹脂不會從金屬板20脫落的大小即可。例如，在貫穿孔23a的開口部22為圓形的情況下，可列舉開口部22的直徑為1.0mm以上且10.0mm以下。
貫穿孔23a的穿孔可以在與將上述素材板衝裁成特定的形狀的同時執行。藉著將上述衝裁步驟和凹部形成步驟同時執行，可以省略步驟且可以有效率地製得具有貫穿孔23a的金屬板20。
[彎曲步驟]
接著，如第1圖的中間圖所示般，將內側開口部22i作為彎曲的內側，而對金屬板20實施彎曲加工。藉著將內側開口部22i作為彎曲的內側而實施彎曲加工，沿著彎曲從彎曲的外側(外側開口部22o)朝向彎曲的內側(內側開口部22i)形成前端尖細之錐狀在貫穿孔23a。
彎曲加工是在例如內側彎曲半徑R及貫穿孔23a之內側開口部22i的直徑d的比率R/d為1.0以下進行。藉著在此比率R/d為1.0以下執行彎曲加工，可以將貫穿孔23a的錐形的延長線上的交點中之角度θ形成約60度以上，並且可以在比率R/d為0的時候將上述角度θ實質上形成90度，而可以將複合構件1的內部空間加以擴大。因而，對貫穿孔23a充填樹脂，並且以到達金屬板20之彎曲部21的內面的方式形成樹脂構件30的時候，可以讓充填於貫穿孔23a的樹脂不易從金屬板20脫落。
[樹脂充填步驟]
接著，如第1圖的下圖所示般，對貫穿孔23a充填樹脂，並且使樹脂成形為經過內側開口部22i的緣部而到達彎曲部21的內面。樹脂的成形可列舉如將金屬板20當中之凹部23的形成部位附近配置於模具，且將未硬化的樹脂注入模具內的射出成型。
藉由上述複合構件的製造方法所製造的複合構件1，如第1圖的下圖所示般，在形成於金屬板20之彎曲部21的錐狀的貫穿孔23a內充填樹脂(內側樹脂部 31)，與內側樹脂部31連接，且以經過內側開口部22i的緣部而到達彎曲部21的內面的方式形成樹脂(露出樹脂部32)。因為貫穿孔23a於內側開口部22i側形成前端尖細之錐狀，所以藉著內側樹脂部31及露出樹脂部32卡在從錐形面連接至彎曲部21的內面的區域，可以將金屬板20和樹脂構件30牢固地接合。
《複合構件和後裝式零件的卡合》
在將樹脂構件30作為後裝式零件的安裝部的情況下，只要形成可以將兩者機械地接合的形狀即可。
例如如第2圖所示般，對樹脂構件30當中之露出樹脂部32實施螺絲加工而形成母螺絲部fs。在此情況下，藉著將樹脂構件30的母螺絲部fs和後裝式零件100的公螺絲部ms加以螺合，可以將後裝式零件100安裝於複合構件1。相反地，例如將突出部(未圖示)形成在露出樹脂部32，對此突出部實施螺絲加工而形成公螺絲部。在此情況下，藉著與後裝式零件的母螺絲部螺合，可以將後裝式零件安裝於複合構件1。
其他，例如如第3圖所示般，將錐部t形成在後裝式零件100，而將與錐部t的形狀一致的嵌合部c形成在樹脂構件30當中之露出樹脂部32。嵌合部c可以使用對應於後裝式零件100的錐形t的形狀的圓錐台狀的中心來加以形成。在此情況下，嵌合部c較佳為在後裝式零件100的插入側的開口邊緣附近，設置朝嵌合部c的內側 突出的薄片部。藉著此薄片部薄且容易變形，可以在形成嵌合部c時將中心取出，且可以將後裝式零件100拆裝自如。在樹脂構件30是以橡膠素材形成的情況下，亦可省略此薄片部的形成。相反地，例如將突出部(未圖示)形成在露出樹脂部32，將此突出部形成錐部，而將與錐部的形狀一致的嵌合部形成在後裝式零件。
因為樹脂構件30是形成到達金屬板20之彎曲部21的內面，所以可以發揮保護彎曲部21的內側的角部的效果。另外，在本實施方式中，因為樹脂構件30當中之內側樹脂部31形成在金屬板20外面的角部，所以亦可保護外側的角部。
金屬板20和樹脂構件30的接合部位在例如複合構件1具有底板部和側壁部的框體的情況下，例如如第4圖所示般，設置複數個在金屬板20之彎曲部21的一部分。在此是將相同形狀的兩個樹脂構件30在彎曲部的稜線方向上分開配置。第4圖之上圖是從內側觀看複合構件1的圖，第4圖之下圖是從外側觀看複合構件1的圖。各樹脂構件30當中露出樹脂部32是如第4圖之上圖所示般，從彎曲部21的底板部形成到側壁部，並沿著底板部及側壁部以彼此相同的長度形成。樹脂構件30當中之內側樹脂部31是如第4圖之下圖所示般充填於貫穿孔，內側樹脂部31的外面與金屬板20的外面相同平面。而且，從彎曲部21的外側朝向內側形成如前端尖細般的形狀。內側樹脂部31與露出樹脂部32連接，因為露出樹脂部 32形成經過貫穿孔的內側開口部到達彎曲部21的內面，所以內側樹脂部31和露出樹脂部32是卡在金屬板20而接合。
其他，例如如第5圖所示般，沿著金屬板20之彎曲部21配置單一的樹脂構件30。第5圖的上圖是從內側觀看複合構件1的圖，第5圖的中間圖及下圖是從外側觀看複合構件1的圖。樹脂構件30當中之露出樹脂部32如第5圖的上圖所示般，形成為朝彎曲部21的稜線方向延伸的剖面為L型的長條片狀，並且與從貫穿孔的中心軸沿著底板部及側壁部延伸之露出樹脂部32的長度彼此相等。樹脂構件30當中之內側樹脂部31可列舉如第5圖的中間圖所示般，沿著藉由彎曲所形成之角部的稜線方向等間隔地分開配置的形態。換言之，在凹部形成步驟等間隔地穿孔出三個貫穿孔，在樹脂充填步驟對各貫穿孔充填樹脂而形成內側樹脂部31，並且與各內側樹脂部31連接而形成一個露出樹脂部32。藉著如此設置，而在三處固定住一個露出樹脂部32，可以將樹脂構件30和金屬板20更牢固地加以接合。作為內側樹脂部31的其他形態，可列舉如第5圖的下圖所示般，沿著角部的稜線方向配置一個內側樹脂部31的形態。在此形態的情況下，在凹部形成步驟形成細長之長條狀貫穿孔。在之後的彎曲步驟中形成彎曲部21時，貫穿孔是以朝沿著彎曲部21的稜線方向的方向延伸的方式形成。與一個的內側樹脂部31連接而形成單一的露出樹脂部32。
於從外側觀看複合構件1的時候，藉著將可看見內側樹脂部31的部位形成在所希望的位置，可以具有金屬和樹脂雙方的質感，且可以例如藉著改變樹脂的顏色或在樹脂上施加裝飾來提高設計性。另外，藉著在複合構件1的外側形成內側樹脂部31於須保護的部分，可以保護金屬板20的彎曲所形成的外側角部。
其他，在樹脂構件30為透明或半透明的情況下，藉著在金屬板20的內側配置LED(發光二極體)等的照明，可以藉由點亮照明而透過樹脂構件30朝複合構件1的外側發光。而且，貫穿孔形成從複合構件1的外側觀看為文字形狀的話，可以在彎曲部形成具有發光文字的造型。
<實施方式2>
參照第6圖說明實施方式2的複合構件2。複合構件2的基本的構造與實施方式1的複合構件1相同，僅金屬板20的形態不同。在此，說明此相異處，其他構造則省略說明。
金屬板20，具備可供充填樹脂構件30當中露出樹脂部32的嵌合凹部24。嵌合凹部24例如如第6圖所示般，具有露出樹脂部32的厚度量的深度。藉著如此設置，因為金屬板20和樹脂構件30的接合面積變大，而且露出樹脂部32卡在金屬板20，所以可以將金屬板20和樹脂構件30更牢固地接合。另外，在複合構件2的內 面，可以將露出樹脂部32的內面和金屬板20的內面成為相同平面，且可以擴大內部空間。在此，嵌合凹部24的深度與露出樹脂部32的厚度相同，亦可比露出樹脂部32的厚度小。
<實施方式3>
參照第7圖說明實施方式3的複合構件3。複合構件3的基本的構造與實施方式2的複合構件2相同，僅樹脂構件30的形態不同。在此，說明此相異處，其他構造則省略說明。第7圖的上圖是從內側觀看複合構件3的圖，第7圖的中間圖及下圖是從外側觀看複合構件3的圖。
樹脂構件30當中之露出樹脂部32如第7圖的上圖所示般，具備：朝彎曲部21的稜線方向延伸的剖面為L型的短片狀的L形片32L、及形成於其L形片的大致中心的間隔片32p。而且，L形片32L配置在實施方式2所說明過的嵌合凹部。換言之，在複合構件3的內面，露出樹脂部32的L形片32L的內面和金屬板20的內面是相同平面。樹脂構件30當中內側樹脂部31與參照第5圖的實施方式1相同，可以形成一個或兩個以上。在形成兩個內側樹脂部31的情況下，例如如第7圖的中間圖所示般，沿著藉由彎曲所形成之角部的稜線方向隔著間隔片32p配置。在形成一個內側樹脂部31的情況下，例如如第7圖的下圖所示般，配置成間隔片32p位於角部的稜線方向的中心。
<實施方式4>
參照第8圖說明實施方式4的複合構件4。複合構件4的基本的構造與實施方式1的複合構件1相同，僅金屬板20的凹部23的形態不同。在此，說明此相異處，其他構造則省略說明。
凹部23是在彎曲部21的內側具有內側開口部22i的溝23b。換言之，在彎曲部21的外側不具有開口部且未貫穿。在此的溝自然是指具有某程度的長度的一般的長條狀的凹部，開口部亦包含圓形孔。此溝23b形成從溝23b的底部朝向內側開口部22i成為前端尖細之錐狀。此錐形的傾斜面的角度與實施方式1相同。
溝23b的深度，只要是在對溝23b充填樹脂，並且以到達金屬板20之彎曲部21的內面的方式形成樹脂構件30的時候，充填於溝23b的樹脂不會從金屬板20脫落的深度即可。例如，溝23b的深度可列舉0.2mm以上且3.0mm以下。
藉著凹部23為溝23b，因為複合構件4的外面不存在貫穿孔，所以於從外側觀看複合構件4的時候，可以在複合構件4的外側整體上具有金屬質感。
[產業上的利用可能性]
本發明的複合構件可以適用於可攜裝置或電腦的框體等，期望可安裝各種的零件的構件上。另外，本 發明的複合構件的製造方法，可適合運用於製得各種框體所使用的複合構件。
1‧‧‧複合構件
20‧‧‧金屬板
21‧‧‧彎曲部
22i‧‧‧內側開口部
22o‧‧‧外側開口部
23‧‧‧凹部
23a‧‧‧貫穿孔
31‧‧‧內側樹脂部
32‧‧‧露出樹脂部
P‧‧‧衝頭

Claims (10)

  1. 一種複合構件，具備：具有由彎曲加工所形成之彎曲部的金屬板、及接合於前述彎曲部之至少一部分的樹脂構件，前述金屬板具有：形成於前述彎曲部之內側的開口部；及從前述彎曲部的外側朝向前述開口部形成前端尖細之錐狀的凹部，前述樹脂構件具有：被充填於前述凹部內的內側樹脂部；及與前述內側樹脂部連接，且形成經過前述開口部的緣部而到達前述彎曲部之內面的露出樹脂部。
  2. 如申請專利範圍第1項所記載的複合構件，其中前述凹部為貫穿孔。
  3. 如申請專利範圍第1項所記載的複合構件，其中前述凹部為溝。
  4. 如申請專利範圍第1項所記載的複合構件，其中前述金屬板，具備可供前述露出樹脂部充填的嵌合凹部。
  5. 如申請專利範圍第2項所記載的複合構件，其中前述金屬板，具備可供前述露出樹脂部充填的嵌合凹部。
  6. 如申請專利範圍第3項所記載的複合構件，其中前述金屬板，具備可供前述露出樹脂部充填的嵌合凹部。
  7. 如申請專利範圍第1、2、3、4、5或6項所記載的複合構件，其中前述複合構件為電氣機器的框體。
  8. 一種複合構件的製造方法，具備：準備步驟，用來準備平板狀的金屬板；和凹部形成步驟，在前述金屬板實施彎曲加工之部位的至少一部分，形成具有開口部的凹部；和彎曲步驟，將前述開口部作為彎曲的內側，而對前述金屬板實施彎曲加工；及樹脂充填步驟，對前述凹部內充填樹脂，並使樹脂成形為經過前述開口部的緣部而到達前述金屬板之彎曲的內面。
  9. 如申請專利範圍第8項所記載之複合構件的製造方法，其中前述準備步驟，具備將素材板衝裁成特定形狀而形成前述平板狀金屬板的衝裁步驟，與前述衝裁步驟同時執行前述凹部形成步驟，穿孔形成貫穿前述素材板兩面的貫穿孔，進而形成凹部。
  10. 一種複合構件，是藉由如申請專利範圍第8項所記載之複合構件的製造方法所製造。
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