COMPOSITE STRUCTURE OF FIBER-REINFORCED PLASTIC SHEET AND METAL SHEET, AND METHOD FOR MANUFACTURING SAME

Conventional manufacturing method of a composite structure having a fiber reinforced member and a metallic sheet bonded each other still has room for improvement in manufacturing cost and bonding strength. A manufacturing method of a composite structure has following features: (a)preparing: a metallic sheet(s) having a through-hole(s) penetrating throughout the metallic sheet(s) in its thickness direction; a prepreg(s) to constitute a fiber reinforced plastic sheet(s); a pair of dies for molding a composite structure in a predetermined shape, wherein pair of dies can have a recess(es) arranged at a position(s) opposed to one side opening(s) of the through-hole(s), the recess(es) having a larger diameter than the one side opening, and a patch member(s) to be set at a position(s) opposed to the through-hole(s); (b)setting the prepreg(s) and the metallic sheet in the dies; (c)closing the dies, wherein, upon closing, (ca)the prepreg(s) and the metallic sheet are molded to the predetermined shape, while surface-contacting therebetween, (cb)at least one of the prepreg(s) and the patch member(s) is extruded into the through-hole(s), so that the shaft part is molded, and (cc)the patch member(s) forms at least part of a head part(s) in the recess(es), the head part(s) integrated with the shaft part(s) and engaging with on the metallic sheet(s).