Method of manufacturing molded product and molded product

{
  "publication_number": "US11786992B2",
  "country": "US",
  "kind": "B2",
  "title": "Method of manufacturing molded product and molded product",
  "abstract": "Provided is a method of manufacturing a molded product that can reduce problems on a reinforcing plate during pressing. In one aspect of the present disclosure, the method of manufacturing a molded product includes welding a first metal plate overlaid with a second metal plate to the second metal plate; and pressing the first metal plate and the second metal plate together. In the pressing, a base surface and a wall surface are formed on the first metal plate; the wall surface is disposed to cross the base surface. In the welding, a first welding is performed on a reinforcing portion of the second metal plate that is overlaid on an area of the first metal plate that is formed into the wall surface; and subsequently, a second welding is performed in a direction crossing a direction of the first welding.",
  "claims": [
    "1. A method of manufacturing a molded product, the method comprising: welding a first metal plate overlaid with a second metal plate to the second metal plate; and pressing the first metal plate and the second metal plate together, wherein, in the pressing, a first base surface, a first wall surface, a bottom surface, and a first curved portion are formed on the first metal plate, the first wall surface being disposed to cross the first base surface, the bottom surface being arranged opposite the first base surface with respect to the first wall surface and crossing the first wall surface, and the first curved portion coupling the first wall surface and the bottom surface to each other, wherein, in the welding, a first welding is performed on a first reinforcing portion of the second metal plate that is overlaid on an area of the first metal plate that is formed into the first wall surface; and subsequently, a second welding in a direction crossing a direction of the first welding and a third welding in a direction parallel to the direction of the second welding are performed on the first reinforcing portion, and only a supplemental welding is performed on a supplemental reinforcing portion of the second metal plate that is overlaid on an area of the first metal plate that is formed into the bottom surface, the supplemental welding being performed in a direction parallel to a ridge line of the first curved portion, wherein the direction of the first welding and the direction of the second welding are straight, wherein the first welding and the second welding do not reach the supplemental reinforcement portion, wherein the supplemental welding is performed positionally separated from the first welding and the second welding, wherein the second welding extends from one end of the first welding, wherein the third welding extends from an other end of the first welding that opposes the one end, and wherein, on the first reinforcing portion, only the first welding, the second welding, and the third welding are performed.",
    "2. The method of manufacturing the molded product according to claim 1, wherein the direction of the first welding is parallel to the ridge line of the first curved portion, and wherein the direction of the second welding is orthogonal to the direction of the first welding.",
    "3. The method of manufacturing the molded product according to claim 1, wherein, in the welding, the first welding and the second welding are performed with laser welding or plasma welding.",
    "4. A molded product comprising: a first metal plate including a first base surface, a first wall surface crossing the first base surface, a bottom surface arranged opposite the first base surface with respect to the first wall surface and crossing the first wall surface, and a first curved portion coupling the first wall surface and the bottom surface to each other; a second metal plate overlaid on and welded to at least the first wall surface of the first metal plate; a first welding bead disposed on a first reinforcing portion of the second metal plate, the first reinforcing portion being overlaid on the first wall surface of the first metal plate; a second welding bead disposed on the first reinforcing portion of the second metal plate; a third welding bead disposed on the first reinforcing portion of the second metal plate; and a supplemental welding bead disposed on a supplemental reinforcing portion of the second metal plate, the supplemental reinforcing portion being overlaid on the bottom surface of the first metal plate, wherein a welding direction of the first welding bead and a welding direction of the second welding bead cross each other, wherein the first welding bead and the second welding bead are formed linearly, wherein the first welding bead and the second welding bead do not reach the supplemental reinforcing portion, wherein a welding direction of the supplemental welding bead is parallel to a ridge line of the first curved portion, wherein the supplemental welding bead is separated from the first welding bead and the second welding bead, wherein only the supplemental welding bead is disposed on the supplemental reinforcing portion, wherein a welding direction of the third welding bead is parallel to the welding direction of the second welding bead, wherein the second welding bead extends from one end of the first welding bead, wherein the third welding bead extends from an other end of the first welding that opposes the one end, and wherein only the first welding bead, the second welding bead, and the third welding bead are disposed on the first reinforcing portion.",
    "5. The molded product according to claim 4, wherein the welding direction of the first welding bead is parallel to the ridge line of the first curved portion, and wherein the welding direction of the second welding bead is orthogonal to the welding direction of the first welding bead."
  ],
  "description_excerpt": "The present disclosure relates to a method of manufacturing a molded product and the molded product.\n\nA method of obtaining a molded product by overlaying a reinforcing plate on a metal plate, which is a base material; welding the reinforcing plate with the metal plate; and pressing a portion of the metal plate overlaid with the reinforcing plate for drawing is publicly known (see Japanese Unexamined Patent Application Publication No. 2016-124029).\n\nIn the method described above, if the position of the reinforcing plate with respect to the base material is offset during the pressing, then this problem of positional offset decreases the quality of the molded product. Such positional offset can be reduced by increasing a welding length of the reinforcing plate.\n\nNevertheless, hardness of the welded portion of the reinforcing plate increases by quenching performed during the welding, which decreases ductility of the welded portion. Accordingly, an increase in the welding length of the reinforcing plate may cause problems such as a breakage on the welded portion during the pressing.\n\nOne aspect of the present disclosure preferably provides a method of manufacturing a molded product that can reduce problems on the reinforcing plate during the pressing.\n\nOne aspect of the present disclosure is a method of manufacturing a molded product. The method includes welding a first metal plate overlaid with a second metal plate to the second metal plate; and pressing the first metal plate and the second metal plate together. In the pressing, a base surface and a wall surface are formed on the first metal plate.",
  "cpc": [
    "B23K 26/26",
    "B21D 22/20",
    "B21D 22/203",
    "B21D 35/007",
    "B23K 10/02",
    "B23K 2101/28",
    "B23K 2103/20",
    "B23K 26/0093",
    "B23K 26/21",
    "B23K 26/244",
    "B23K 26/323",
    "B23K 31/02"
  ],
  "ipc": [
    "B23K 10/02",
    "B23K 26/00",
    "B23K 26/26",
    "B21D 35/00",
    "B23K 26/21"
  ],
  "assignees": [
    "Futaba Industrial Co Ltd"
  ],
  "inventors": [
    "Shota Muto",
    "Keigo Yasuda",
    "Koji Yamaguchi"
  ],
  "filing_date": "2021-01-15",
  "publication_date": "2023-10-17",
  "grant_date": "2023-10-17",
  "priority_date": "2020-03-13",
  "application_number": "US-202117150583-A",
  "family_id": "77457633",
  "cited_by_count": 1,
  "citations": [
    "JP2000197969A",
    "JP2014015206A",
    "US20140147693A1",
    "JP2015166099A",
    "JP2016124029A",
    "US20190010570A1",
    "CN110582359A",
    "JP6642777B1",
    "US20210197525A1",
    "US20200316668A1",
    "JP2020168647A"
  ]
}