JP2009073088A - Insert molded article and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an insert molded article excellent in productivity and in which an insert member of metal and a resin member is firmly bonded and a manufacturing method of the insert molded article. <P>SOLUTION: In the insert molded article 1 constituted by forming the resin layer 3 on the face 2a to be adhered of the insert member 2 of metal via the adhesive layer 4, the adhesive layer 4 includes the first adhesive layer 4a arranged in the insert member 2 side and the second adhesive layer 4b arranged in the resin layer 3 side, the first adhesive layer 4a comprises a resin containing an epoxy resin, and the second adhesive layer 4b containing at least one kind of resin selected from a polyester base resin, a polyurethane base resin, and a vinyl base resin. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an insert molded body and a method for manufacturing the insert molded body, and more particularly to an insert molded body in which a metal insert member and an adhesive layer are firmly joined and a method for manufacturing the insert molded body.

  Conventionally, composite products in which metal members such as aluminum and aluminum alloys and resin members are integrated are automobile interior parts such as console boxes around instrument panels, interior parts, and electronic devices such as digital cameras and mobile phones. It is used for exterior members. As a method of integrating the metal member and the resin member, a method of adhering using an adhesive or a double-sided tape, a fixing member such as a folded piece or a nail is provided on the metal member and / or the resin member, and this fixing member is used. There are a method of fixing them using a method, a method of bonding using screws, and the like.

  Specifically, for example, there is an automobile console box in which an aluminum panel and a resin member are integrated using a fixing member made of a folded piece and a double-sided tape. However, in this automobile console box, there is a possibility that the aluminum panel and the resin member are partially separated due to a temperature change in the automobile. In addition, in the console box of this automobile, there is a space that is not in close contact between the aluminum panel and the resin member, so that the aluminum panel is easily deformed, and there is no sense of quality when tapping. There was also an inconvenience. For this reason, in the console box of such a motor vehicle, it was requested | required that the aluminum panel and the resin member should be closely_contact | adhered, and that the joining strength of an aluminum panel and the resin member should be improved.

  In addition, a composite product in which a metal member and a resin member are integrated using the above method must be formed after the metal member shape process and the resin member molding process are separately performed. There is a problem that it takes time and effort. Furthermore, when a metal member and a resin member are integrated using said method, there also exists a problem that the joining force of a metal member and a resin member is inadequate.

In order to solve this problem, an anodized film is formed on the surface of the aluminum material, the aluminum material on which the anodized film is formed is placed in the cavity of the mold, and a resin is injected into the cavity to A technique for manufacturing a composite product with a synthetic resin molded body has been proposed (see, for example, Patent Document 1).
In addition, a method for manufacturing a metal insert resin composite molded product is proposed in which the surface of a metal part is chemically etched in advance, and then the metal part is inserted into a mold of an injection molding machine and injection molded using a thermoplastic resin material. (For example, refer to Patent Document 2).

By using the techniques described in Patent Document 1 and Patent Document 2, the molding process of the resin member and the integration of the metal member and the resin member can be performed at the same time, so that productivity can be improved. Moreover, while using the technique of patent document 1 or patent document 2, while being able to adhere | attach a metal member and a resin member, the joining force of a metal member and a resin member can be improved.
International Publication No. 2004/055248 Pamphlet JP 2001-225352 A

However, in the techniques described in Patent Document 1 and Patent Document 2, it is necessary to process the bonded surface of the insert member made of metal before molding the resin member, which is troublesome. That is, in the technique described in Patent Document 1, an anodized film must be formed on the surface of an aluminum material, and in the technique described in Patent Document 2, the surface of a metal part must be chemically etched.
In order to solve this problem, a method in which processing is not performed on the adherend surface of the insert member made of metal is conceivable. However, in the techniques described in Patent Document 1 and Patent Document 2, the insert member made of metal If the surface to be bonded was not processed, the bonding force between the metal member and the resin member could not be obtained sufficiently. For this reason, it is difficult to improve productivity with the techniques described in Patent Document 1 and Patent Document 2.

  The present invention has been made in view of such circumstances, and has an excellent productivity, and an insert molded body in which a metal insert member and a resin member are firmly bonded, and a method of manufacturing the insert molded body. The issue is to provide.

  The insert molded body of the present invention is an insert molded body in which a resin layer is formed on an adherend surface of an insert member made of metal via an adhesive layer, and the adhesive layer is provided on the insert member side. The first adhesive layer and the second adhesive layer provided on the resin layer side, wherein the first adhesive layer is made of a resin containing an epoxy resin, The adhesive layer 2 includes at least one resin selected from a polyester resin, a polyurethane resin, and a vinyl resin.

In the insert molded body of the present invention, the metal may be at least one selected from aluminum, an aluminum alloy, and an iron-based alloy.
In the insert molded body of the present invention, the resin layer may contain at least one selected from acrylonitrile / butadiene / styrene resin, polycarbonate resin, and acrylic resin.

  In the method for producing an insert molded body of the present invention, an adhesive layer is formed by forming a first adhesive layer and a second adhesive layer in this order on the adherend surface of an insert member made of metal. A step of forming a layer, a step of placing the insert member in which the adhesive layer is formed in a cavity of a mold, and supplying and curing a molten resin in the cavity, thereby A molding step of forming a resin layer formed by bonding the resin to the surface to be bonded through the adhesive layer, and the first adhesive layer is made of a resin containing an epoxy resin, The second adhesive layer includes at least one resin selected from a polyester resin, a polyurethane resin, and a vinyl resin.

In the method for producing an insert molded body of the present invention, the metal may be at least one selected from aluminum, an aluminum alloy, and an iron-based alloy.
Moreover, in the manufacturing method of the insert molded object of this invention, it can be set as the method in which the said resin layer contains at least 1 sort (s) chosen from acrylonitrile * butadiene * styrene resin, polycarbonate resin, and acrylic resin.

  In the insert molded body of the present invention, the first adhesive layer is made of a resin containing an epoxy resin, and the second adhesive layer is selected from a polyester resin, a polyurethane resin, and a vinyl resin. Since it contains at least one kind of resin, the first adhesive layer has excellent adhesion and adhesiveness to the metal insert member, and the second adhesive layer adheres to the resin layer. By being excellent in property, an insert molded body in which an insert member made of metal and a resin member are firmly bonded is obtained. Therefore, in the insert molded body of the present invention, a sufficiently high joining force can be obtained even if the insert member made of metal is not processed on the adherend surface.

  Moreover, the manufacturing method of the insert molded object of this invention forms the adhesive bond layer by which the 1st adhesive bond layer and the 2nd adhesive bond layer are formed in this order on the to-be-adhered surface of the insert member which consists of metals. An adhesive layer forming step, wherein the first adhesive layer is made of a resin containing an epoxy resin, and the second adhesive layer is selected from a polyester resin, a polyurethane resin, and a vinyl resin; Since it contains at least one or more kinds of resin, an insert molded body in which the insert member made of metal and the resin member are firmly bonded can be obtained. Moreover, in the method for manufacturing an insert molded body of the present invention, it is not necessary to process the bonded surface of the insert member made of metal, and the molding process of the resin member and the integration of the metal member and the resin member are performed. Since it can be performed at the same time, the method is superior in productivity as compared with the conventional manufacturing method.

Hereinafter, examples of the insert molded body and the method for manufacturing the insert molded body according to the present invention will be described in detail.
FIG. 1 is a cross-sectional view showing an example of an insert molded body of the present embodiment. FIG. 2 is a schematic process diagram for explaining an example of a method for producing the insert molded body shown in FIG.
As shown in FIG. 1, the insert molded body 1 of the present embodiment is formed by forming a resin layer 3 on an adherend surface 2 a of an insert member 2 having a U-shaped cross-sectional view through an adhesive layer 4. .

  The insert member 2 is made of a metal such as aluminum, an aluminum alloy, an iron-based alloy such as stainless steel, copper, a copper alloy, and the like, and is lightweight and highly corrosion-resistant aluminum or aluminum alloy or stainless steel having excellent durability and strength. An iron-based alloy such as steel is preferably used.

As the resin layer 3, acrylonitrile / butadiene / styrene resin (ABS), polycarbonate resin (PC), acrylic resin (PMMA), polyethylene resin, polyvinyl chloride resin, polyamide resin, polyacetal resin, polybutylene terephthalate resin, polyethylene terephthalate resin And a thermoplastic resin mainly composed of at least one resin selected from the group consisting of polyphenylene sulfide resin, liquid crystalline polyester resin, polyimide resin, syndiotactic polystyrene resin, and polycyclohexanedimethylene terephthalate resin. Those are preferably used. Among these, since it can be firmly bonded to the insert member 2 by the adhesive layer 4, it is preferable to use a resin mainly composed of ABS, PC, PMMA, and a resin mainly composed of a resin mainly composed of ABS. Most preferably, it is used.
In addition to the above resin, the resin layer 3 may contain various conventionally known fillers such as silica, and additives such as a heat stabilizer, a release agent, and a plasticizer.

As shown in FIG. 1, the adhesive layer 4 includes a first adhesive layer 4 a provided on the insert member 2 side and a second adhesive layer 4 b provided on the resin layer 3 side.
The first adhesive layer 4a is made of a resin containing an epoxy resin, and in particular, a cured bisphenol A liquid epoxy resin or the like is preferably used. Specifically, what hardened S-25 (brand name: Toyo Ink Manufacturing Co., Ltd. product) etc. are mentioned.
The second adhesive layer contains at least one resin selected from polyester resins, polyurethane resins, and vinyl resins. Specifically, JELCON B-2 binder (trade name: manufactured by Jujo Chemical Co., Ltd.), JELCON G-2S binder (trade name: manufactured by Jujo Chemical Co., Ltd.), JELCON A-5 binder (trade name: Jujo Chemical Co., Ltd.) And the like obtained by curing the product.

In order to manufacture the insert molded body shown in FIG. 1, first, a first adhesive that becomes the first adhesive layer 4 a is applied to the adherend surface 2 a of the insert member 2 and dried. The adhesive layer 4a is formed. The first adhesive used here is a resin containing an epoxy resin, and at least one solvent selected from methyl isobutyl ketone, trimethylbenzene (1,3.5-trimethylbenzene), an aromatic hydrocarbon solvent, and the like. Is included.
More specifically, 1 to 5% of bisphenol A type epoxy resin as a resin, 30 to 40% of methyl isobutyl ketone as a solvent, 20 to 30% of trimethylbenzene, and 1 to 5 of 1,3.5-trimethylbenzene. %, Those containing 20-30% of aromatic hydrocarbon solvent can be preferably used. Moreover, it is preferable that the thickness of the 1st adhesive bond layer 4a shall be 0.1-10 micrometers, for example.

Next, a second adhesive layer 4b is formed by applying and drying a second adhesive to be the second adhesive layer 4b on the first adhesive layer 4a. The second adhesive used here is at least one resin selected from polyester resins, polyurethane resins, and vinyl resins, cyclohexanone, 3-methoxy-3-methylbutyl acetate, and aromatic mixed hydrocarbons. And at least one solvent selected from (petroleum naphtha), isophorone, toluene and the like. Moreover, it is preferable that the thickness of the 2nd adhesive bond layer 4b shall be 1-30 micrometers, for example.
The drying for forming the second adhesive layer 4b may be performed at room temperature, but if the solvent remains in the second adhesive layer 4b, the adhesiveness with the resin layer 3 decreases. Therefore, for example, it is preferable to dry completely by carrying out at a temperature of 70 ° C. to 80 ° C. for about 30 minutes to 1 hour.
As a result, as shown in FIG. 2A, the adhesive layer 4 in which the first adhesive layer 4 a and the second adhesive layer 4 b are formed in this order on the adherend surface 2 a of the insert member 2. Is obtained (adhesive layer forming step).

Then, the metal mold | die 5 shown to Fig.2 (a) and FIG.2 (b) is prepared. As shown in FIGS. 2 (a) and 2 (b), the mold 5 used here is composed of a lower mold 5a and an upper mold 5b having an injection port 6a for injecting resin. It is. As shown in FIG. 2B, the mold 5 has a shape corresponding to the shape of the insert molded body 1 when the lower mold 5 a and the upper mold 5 b are closed. It is.
Next, as shown in FIG. 2A, the portion where the adhesive layer 4 is formed is in contact with the resin injected into the mold 5, and the portion where the adhesive layer 4 is not formed is the lower mold 5a. The insert member 2 on which the adhesive layer 4 is formed is disposed in the cavity 6 so as to contact the inner surface of the cavity 6, and the lower mold 5 a and the upper mold 5 b are closed.

Subsequently, a resin made of resin via the adhesive layer 4 is applied to the adherend surface 2a of the insert member 2 by supplying a molten resin to be the resin layer 3 from the inlet 6a into the cavity 6 and curing it. Layer 3 is molded and bonded (molding process).
Thereafter, the insert molded body 1 thus obtained is taken out from the mold 5.

EXAMPLES Next, the present invention will be specifically described with reference to examples, but the present invention is not limited to the examples shown below.
"Example 1"
An insert molded body was produced by the method described below.
First, S-25 (trade name: manufactured by Toyo Ink Manufacturing Co., Ltd.) is used as the first adhesive to be the first adhesive layer on the upper surface (bonded surface) of the insert member made of aluminum having a thickness of 0.6 mm. The first adhesive layer was formed by applying and drying. Next, by applying a JELCON B-2 binder (trade name: manufactured by Jujo Chemical Co., Ltd.) as a second adhesive to be the second adhesive layer on the first adhesive layer and drying, Thus, an adhesive layer was obtained in which a first adhesive layer having a thickness of 0.5 μm and a second adhesive layer having a thickness of 3 μm were formed in this order on the upper surface of the insert member.

  Subsequently, the insert member on which the adhesive layer was formed was disposed in the cavity so that the lower surface was in contact with the inner surface of the cavity of the mold, and the lower mold and the upper mold were closed. Thereafter, molten ABS serving as a resin layer is supplied into the cavity from the injection port and cured to form a resin layer, which is taken out of the mold and has a thickness of 3.1 mm (insert member thickness of 0.6 mm). An insert molded body of Example 1 having a resin layer thickness of 2.5 mm was obtained.

"Example 2"
An insert molded body of Example 2 was obtained in the same manner as Example 1 except that ABS containing 30% by mass of a glass filler was used as the resin layer.

"Example 3"
Insert molded body of Example 3 in the same manner as in Example 2 except that JELCON G-2S binder (trade name: manufactured by Jujo Chemical Co., Ltd.) was used as the second adhesive serving as the second adhesive layer. 1 was obtained.

Example 4
The insert molded body of Example 4 in the same manner as Example 2 except that JELCON A-5 binder (trade name: manufactured by Jujo Chemical Co., Ltd.) was used as the second adhesive serving as the second adhesive layer. Got.

"Example 5"
An insert molded body of Example 5 was obtained in the same manner as Example 1 except that ABS containing 50% by mass of PC was used as the resin layer.

"Comparative Example 1"
An insert molded body of Comparative Example 1 was obtained in the same manner as in Example 1 except that the second adhesive layer was not present.
"Comparative Example 2"
An insert molded body of Comparative Example 2 was obtained in the same manner as in Example 1 except that the first adhesive layer was not provided.
“Comparative Example 3”
An insert molded article of Comparative Example 3 was obtained in the same manner as Example 1 except that there was no adhesive layer.

The tensile tests shown below were performed twice for the insert molded bodies of Examples 1 to 5 and Comparative Examples 1 to 3 thus obtained.
The results are shown in Table 1.

"Tensile test"
A sample having a width of 20 mm was cut out from the flat portion of the insert molded body, and the insert member 2b was peeled off from the resin layer 3b over a length of 20 mm as shown in FIG. The maximum value of the tensile strength at that time was measured.

As shown in Table 1, in the insert molded bodies of Examples 1 to 5, the results of the tensile test were all 1 Kg or more, and sufficient strength was obtained. In particular, in the insert molded bodies of Example 1, Example 2, and Example 5 using B-2 as the second adhesive, the tensile test results were 6 kg or more, and very high strength was obtained. .
On the other hand, in the insert molded articles of Comparative Examples 1 to 3, all the tensile test results were less than 0.1 kg.

Moreover, the thermal cycle load test of -40 degreeC-90 degreeC and 10 cycles was done with respect to the insert molded object of Example 1, Example 2, Example 5, and the comparative example 1. FIG.
As a result, in the insert molded body of Comparative Example 1, the insert member and the resin layer were peeled off.
On the other hand, in the insert molded bodies of Example 1, Example 2, and Example 5, no peeling occurred. Therefore, it was confirmed that the insert molded bodies of Example 1, Example 2, and Example 5 were sufficiently high in strength against temperature change.

FIG. 1 is a cross-sectional view showing an example of an insert molded body of the present embodiment. FIG. 2 is a schematic process diagram for explaining an example of a method for producing the insert molded body shown in FIG. FIG. 3 is a perspective view showing a tensile test sample for explaining the tensile test method.

Explanation of symbols

    DESCRIPTION OF SYMBOLS 1 ... Insert molded object, 2 ... Insert member, 2a ... Bonded surface, 3 ... Resin layer, 4 ... Adhesive layer, 4a ... 1st adhesive layer, 4b ... 2nd adhesive layer, 5 ... Mold 5a ... lower mold, 5b ... upper mold, 6 ... cavity, 6a ... injection port.

Claims (6)

An insert molded body in which a resin layer is formed on an adherend surface of an insert member made of metal via an adhesive layer,
The adhesive layer consists of a first adhesive layer provided on the insert member side and a second adhesive layer provided on the resin layer side,
The first adhesive layer is made of a resin containing an epoxy resin,
The insert molded body, wherein the second adhesive layer contains at least one resin selected from polyester resins, polyurethane resins, and vinyl resins.   The insert molded body according to claim 1, wherein the metal is at least one selected from aluminum, an aluminum alloy, and an iron-based alloy.   The insert molded body according to claim 1 or 2, wherein the resin layer contains at least one selected from acrylonitrile / butadiene / styrene resin, polycarbonate resin, and acrylic resin. An adhesive layer forming step of forming the adhesive layer by forming the first adhesive layer and the second adhesive layer in this order on the adherend surface of the insert member made of metal;
Disposing the insert member formed with the adhesive layer in a cavity of a mold;
A molding step of forming a resin layer in which the resin is molded and bonded to the surface to be bonded of the insert member via the adhesive layer by supplying and curing the molten resin into the cavity. Prepared,
The first adhesive layer is made of a resin containing an epoxy resin,
The method for producing an insert molded article, wherein the second adhesive layer contains at least one resin selected from a polyester resin, a polyurethane resin, and a vinyl resin.   The method for producing an insert molded body according to claim 4, wherein the metal is at least one selected from aluminum, an aluminum alloy, and an iron-based alloy.   The method for producing an insert molded article according to claim 4 or 5, wherein the resin layer contains at least one selected from acrylonitrile / butadiene / styrene resin, polycarbonate resin, and acrylic resin.

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