CN115666908A - 一种金属-聚合物复合零件及其制造方法 - Google Patents

一种金属-聚合物复合零件及其制造方法 Download PDF

Info

Publication number
CN115666908A
CN115666908A CN202180036107.XA CN202180036107A CN115666908A CN 115666908 A CN115666908 A CN 115666908A CN 202180036107 A CN202180036107 A CN 202180036107A CN 115666908 A CN115666908 A CN 115666908A
Authority
CN
China
Prior art keywords
functional layer
metal
polymer
layer
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202180036107.XA
Other languages
English (en)
Inventor
R·贝姆
P·斯皮斯
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF SE
Original Assignee
BASF SE
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BASF SE filed Critical BASF SE
Publication of CN115666908A publication Critical patent/CN115666908A/zh
Pending legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1658—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning once, e.g. contour laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/939—Measuring or controlling the joining process by measuring or controlling the speed characterised by specific speed values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/959—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables
    • B29C66/9592—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables in explicit relation to another variable, e.g. X-Y diagrams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/088—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyamides
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2039—Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0007—Casings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled

Landscapes

  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Electromagnetism (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Thermal Sciences (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

本发明涉及一种金属‑聚合物复合材料零件的制造方法、所述金属‑聚合物复合材料零件本身和一种层压组件。对电气或电子组件和机械结构件而言，外壳通常由聚合物复合材料零件组成，所述聚合物复合零件特别是含有热塑性基材和聚合物金属复合材料，其中，不同的材料具有不同的功能。作为一种半成品，聚合物金属复合材料适合用于电磁屏蔽，作为扩散屏障，例如针对油、燃料的扩散屏障和用于电子产品外壳的冷却介质，用于从外壳内部进行散热，以及用于防止磨损。聚合物复合材料零件被用于结构和外部轮廓方面，其能够组成具有复杂几何形状的结构件,用于连接其他结构件和容纳放置电子元件以及插件。因此，聚合物金属复合材料在本领域内被广泛熟知。

Description

一种金属-聚合物复合零件及其制造方法
本发明涉及一种金属-聚合物复合材料零件的制造方法、该金属-聚合物复合材料零件本身和一种层压组件。
对于电气或电子组件领域和机械结构件而言，外壳通常由聚合物复合材料零件组成，所述聚合物复合材料零件特别是含有热塑性基材和聚合物金属复合材料，其中，不同的材料具有不同的功能。作为一种半成品，聚合物金属复合材料适合用于电磁屏蔽，作为扩散屏障，例如针对油、燃料的扩散屏障，作为电子产品外壳的冷却介质，用于从外壳内部进行散热，以及用于防止磨损。聚合物复合材料零件被用于结构和外部轮廓，使得能够组成具有复杂几何形状的结构件，用于连接至其他结构件和容纳放置电子元件或插件。因此，聚合物金属复合材料在本领域内被广泛熟知。
例如，DE102004045402A1描述了一种含有金属涂料的注射成型的塑料支撑件，该金属涂料形成了模制品的一部分。该涂料能够设置在支撑件的两面，且该涂料在放进注射工具前是预成型的状态。进一步地，制造该组件的方法描述如下：其中，a)将形成涂料的金属箔片放置在注射成型的工具中，并固定，将工具封闭；b)将塑性材料注入工具中，使塑性材料与涂料粘结至形成支撑件。
此外，从DE10361096A1可知一种组件及其制造方法。该组件至少部分地由金属形成，金属区至少部分地通过注射成型的热塑性材料进行封装。在塑料与金属区之间至少在一些区域设置有粘结促进层，所述粘结促进层至少在其面向塑料的那一面由热塑性材料组成，通过这种方式使得金属区和塑料之间存在非主动(non-positive)连接。粘结促进层被应用于至少部分金属区，其中在粘结促进层和金属区之间形成有至少一种非主动连接。随后，塑料以这样一种方式模塑成型：面向设置在金属区上的粘合剂层的塑料的至少表面区域被塑化的塑料熔化并至少在一些区域与喷涂的塑料焊接。
此外，DE102018207205A1涉及一种金属/复合材料的复合组件，特别涉及一种外壳或外壳零件，在所述金属/复合材料中包含有至少一层金属片和至少一个通过材料锁固和/或外形锁固的方式施用于该金属片的热塑性材料、热固性(硬质塑料)或弹性塑料层，该金属片用于屏蔽电磁辐射、动电或静电和/或动磁场或静磁场。这种复合组件的特征在于其在动磁场或频率v为0.001kHz至1000kHz的动电磁场中具有1.00dB至120.00dB的屏蔽因子S(v)，其中屏蔽因子S(v)是根据槽和源之间有或没有复合组件时在槽的位置测得的场强系数计算得到的。而且，该现有技术还涉及该复合组件的制造方法和应用。
根据现有技术，金属组件和聚合物组件在PMH(PMH:聚合物金属复合材料)结构下的结合能够通过不同方式实施。这两种组件都能够通过胶进行结合，但是，这种方法给整体系统添加了另一种材料类型和另一个工艺步骤，且胶的硬化导致了更长的周期时间。另一种可能的方案是使用粘合剂/底剂，然而，由于不同线性热膨胀系数(CLTE)以及金属和聚合物之间相对较薄的边界层导致的热张力，粘合剂/底剂的操作稳定性较差。其他的设想是基于外形锁固结合，但这种方式具有注射成型工具带来的几何局限性。此外，在这种技术方案下空心体不具有可加工性。另一种可能的方案是注塑成型工艺中带有聚合物的金属零件的重叠注塑(over-moulding)。最后，可使用螺栓或螺钉一类的紧固件，但这种方法在制造中仍然会引入一种额外的材料类型和额外的工艺步骤。
前文所提及的方法和组件存在一些缺点，例如昂贵的模具、复杂的处理工艺以及重叠注塑带来的线性热膨胀系数差异行为，或者是因采用胶而导致的较长的固化和硬化时间。
因此，需要一种能够克服上述缺点的有利的聚合物金属复合材料制造方法和一种有利的聚合物金属复合材料。
本发明的目的在于提供一种有利的金属-聚合物复合材料零件的制造方法以及该金属-聚合物复合材料零件本身，该复合材料零件具有增强的结合稳定性以及实用性。本发明的另一目的在于提供一种金属和聚合物层压组件，该层压组件能够通过众所周知的金属加工技术进行加工。
上述问题在本发明的第一方面通过金属-聚合物复合材料零件的制造方法解决，该方法包括以下步骤：
a)提供层压组件(1)，其中，层压组件(1)包含至少一层金属层(101)，所述金属层(101)被至少一层第一功能层(103)覆盖，
b)提供聚合物组件(3)，
c)使聚合物组件(3)与层压组件(1)的所述至少一层第一功能层(103)接触，
d)通过物理处理使聚合物组件(3)结合至所述至少一层第一功能层(103)，
e)获得金属-聚合物复合材料零件。
此外，上述问题在本发明的第二方面通过可由本公开内容中详述的本发明方法得到的金属-聚合物复合材料零件解决。
进一步地，上述问题在本发明的第三方面通过一种层压组件(1)解决，该层压组件包括：
-至少一层金属层(101)和
-至少一层第一功能层(103)，所述至少一层第一功能层(103)覆盖所述至少一层金属层(101)，其中所述至少一层第一功能层(103)至少部分地包括一种激光吸收填充材料。
采用本发明的方法可获得金属-聚合物复合材料零件，该零件可以采用标准金属加工工艺进行进一步加工。在制造该产品时，可以使用单一的公知工艺，例如非标准薄膜层压技术或标准结合技术。本发明的金属-聚合物复合材料零件可以用于支撑工程塑料，代表了一种新型的金属薄片涂层。因此，本发明的金属-聚合物复合材料零件特别适合应用于汽车工业领域的轻量化结构。
根据本发明，另一个优势是聚合物组件(3)可以通过标准注塑成型工艺进行生产。可以选取较短的周期时间和其他注塑成型的参数以获得具有理想性能的聚合物组件(3)。而且，聚合物组件(3)和层压组件(1)之间的结合可以在较短的周期时间内得到。建立结合可以稍后在生产流水线中进行(例如，在最后装配期间)。因此，层压组件(1)可在金属加工公司或车间生产，而聚合物组件(3)能够在注塑成型机器中制造。
此外，通过模块化可以提高效率。层压组件(1)代表了一种制式统一的零件，能够与不同类型的聚合物组件(3)结合。在一个生产周期中，一台金属冲压机可以与几台注塑成型机配合工作。进一步地，由于不必考虑脱模、侧凹、肋高和模具设计的其他方面，本发明提供了一种具有高几何自由度的组件。
本发明具体说明如下。
在下述根据本发明的金属-聚合物复合材料零件和/或层压组件(1)的说明中提及的特征同样适用于在本公开内容中说明的根据本发明的方法。同样地，在根据本发明的方法的说明中提及的特征也适用于根据本发明的金属-聚合物复合材料零件和/或层压组件(1)。
在第一方面，本发明涉及一种金属-聚合物复合材料零件的制造方法，该方法包括以下步骤：
a)提供层压组件(1)，其中，层压组件(1)包含至少一层金属层(101)，所述金属层(101)被至少一层第一功能层(103)覆盖，
b)提供聚合物组件(3)，
c)使聚合物组件(3)与层压组件(1)的所述至少一层第一功能层(103)接触，
d)通过物理处理使聚合物组件(3)结合至所述至少一层第一功能层(103)，
e)获得金属-聚合物复合材料零件。
从本发明的意义上说，“金属-聚合物复合材料零件”的表述表示的是一种由金属-聚合物层压结构件和聚合物零件结合而组成的零件。
专有名词“层压组件”用于表示一种至少包含有两层材料的组件，其中一层材料是金属材料，一层材料是聚合物材料，这些材料层以及层压组件具有远低于其宽度和长度的厚度(半二维的)。
聚合物组件(3)可以是纯聚合物材料零件，但也可以包含有非聚合物材料的成分，例如填充材料、增强材料、颜料等。聚合物组件(3)的材料是一种热塑性材料，优选地，可以选自热塑性聚氨酯(TPU)和聚酰胺，尤其是选自PA6、PA66、PA6/66、PA66/6、PA6T/6、PA6.10、PA6.12、PA12、PA9T、PA6I/6T、PA6T/6I、PA6/6.36或者其组合。特别适用于聚醚嵌段聚酰胺，如聚醚二胺与脂肪族二元羧酸(C4-C40)和/或内酰胺(C6-C12)如己内酰胺或十二内酰胺的共聚物、脂肪族二胺(C4-C10)与脂肪族二元羧酸(C4-C40)的共聚物、内酰胺(C6-C12)的缩聚物、内酰胺和/或脂肪族二元羧酸与脂肪族二胺的共聚物或其组合。
聚合物组件(3)可以包含其他添加剂，例如玻璃纤维、碳纤维、芳纶纤维或其组合。这些纤维可以通常市售的类型作为粗纱或短切纤维(cutting)掺入。而且，也可使用由上述补强材料组成的机织物、稀松织物、流体、垫和短纤维。
此外，聚合物组件(3)也可以包含冲击改性剂，例如乙烯和α-烯烃和/或丙烯酸酯和/或丙烯酸的顺丁烯二酸酐接枝共聚物、顺丁烯二酸酐和乙烯和/或丙烯酸酯的共聚物、苯乙烯顺丁烯二酸酐(SMA)、顺丁烯二酸酐接枝聚丙烯。
总体来说，所述至少一层第一功能层(103)可以包括任何热塑性聚合物材料。优选的聚合物材料列出如下。
优选地，金属层(101)的厚度可以为0.01mm—2.0mm。作为材料，铝、钢、热浸镀钢或电镀钢是特别优选的。金属层(101)被调节至具有可深拉伸性。
在一个具体的实施方案中，金属层(101)可以用粘合促进剂/底剂进行预处理，以确保与第一功能层(103)和/或第二功能层(105)具有较好的粘合，粘合促进剂/底剂基于聚丙烯酸、聚甲基丙烯酸、聚丙烯酸酯或聚甲基丙烯酸酯、聚乙烯胺、磷酸、多聚磷酸，以及顺丁烯二酸和丙烯酸和/或甲基丙烯酸和/或丙烯酸酯或甲基丙烯酸酯的共聚物，以及顺丁烯二酸和苯乙烯的共聚物，以及乙烯与丙烯酸和/或甲基丙烯酸和/或丙烯酸酯或甲基丙烯酸酯和/或顺丁烯二酸与聚乙烯吡咯烷酮的共聚物。粘合促进剂/底剂通常作为水基溶液通过辊涂法进行涂布。
根据本发明的方法的步骤a)中提供了一种层压组件(1)，其中层压组件(1)包含有至少一层金属层(101)，所述金属层(101)被至少一层第一功能层(103)覆盖。表述“被覆盖”可理解为金属层(101)被所述至少一层第一功能层(103)覆盖至少一部分，或者甚至被完全覆盖。
可以提供不同形状的层压组件(1)，例如半二维的片状，或者，通过例如深拉伸等可以获得的三维结构。
在步骤b)提供了一种聚合物组件(3)，该组件可以是平板状的零件，也可以是三维的结构件。
在步骤c)中聚合物组件(3)与层压组件(1)的所述至少一层第一功能层(103)接触，特别地，这表示聚合物组件(3)置于功能层(103)的至少一部分的上部。所述至少一层金属层(101)置于与聚合物组件(3)相反的一侧。
在步骤d)中聚合物组件(3)通过物理处理结合至所述至少一层第一功能层(103)，从而在步骤e)得到金属-聚合物复合材料零件。
通过本发明能够得到可经标准金属加工方法进一步加工的金属—聚合物复合材料零件。
可以看出，在制造中，单一的公知工艺，例如非标准薄膜层压技术或标准结合技术以一种目前未知的方式结合了。根据本发明的方法制造的金属-聚合物复合材料零件可用于支撑工程塑料和代表一种新型的金属薄片涂层。
在一个本发明的优选实施方案中，金属-聚合物复合材料零件的制造方法涉及形成外壳，其中层压组件(1)是具有第一沟槽(1a)的三维结构零件，聚合物组件(3)要么是一个大致平板状的零件，要么是一个具有第二沟槽(3a)的三维结构零件，聚合物组件(3)和层压组件(1)两者的结合形成了金属-聚合物复合材料零件，该金属-聚合物复合材料零件包围了沟槽(1a,3a)，从而形成了一个空腔(5)。在空腔(5)中可以放置例如电子器件，电子器件可以受到本发明的金属-聚合物复合材料零件的保护和/或屏蔽。
本发明作为三维结构零件的层压组件(1)可以通过金属加工技术获得，例如深拉伸、拉伸成形、吹塑成形或辊压成形以及冲压，特别是冷加工成形。从而，可以设置最终几何体的最终或初步形状。
根据本发明的聚合物组件(3)可以通过合适的成型工艺获得，例如注射成型、挤出成型、深拉伸或吹塑成型。聚合物组件(3)可能具体体现为加强筋、圆头螺钉或具有无线电集成件的外壳元件。
在本发明方法的一种进一步发展中，物理处理包括激光透射焊接、超声波焊接、摩擦焊接和/或热熔结合。
在超声波焊接或摩擦焊接的情况下，热能的产生受结合部件,即聚合物组件(3)和第一功能层(103)之间和/或内部的内部或外部摩擦所影响。热量的输入通过在聚合物组件(3)和第一功能层(103)的端面进行辐射、接触或对流实施。结合可以通过将熔融表面压到一起而形成。
通过这些物理处理之一，聚合物组件(3)在第一功能层(103)的接触面至少部分地软化和/或熔化，以使这两种聚合物材料能够结合。
在本发明方法的一个非常特别的实施方案中，聚合物组件(3)的材料至少是部分地半透明的(即与第一功能层(103)接触的那部分)。特别地，该聚合物组件(3)的至少部分是可传输激光的。在这个特别的实施方案中，物理处理包括激光透射焊接。
通过实施上述特别的实施方案，激光束(L)被引导到聚合物组件(3)的面向第一功能层(103)的那些部分，使得激光的能量至少部分地透过聚合物组件传输至第一功能层(103)。从而，至少聚合物组件(3)和第一功能层(103)的边界层融化或软化以形成结合。
为提高第一功能层(103)内接收的能量，层压组件(1)至少部分地具有激光吸收性。
尽管金属层(101)和第一功能层(103)之间的边界层可以设置有激光吸收性，但尤为优选在第一功能层(103)内设置激光吸收性。
在本发明的一个非常特别的实施方案中，层压组件(1)和聚合物组件(3)之间形成结合，其中，结合至少部分地为物质锁固的。换句话说，由于聚合物组件(3)和第一功能层(103)之间边界层的软化/融化，实现至少原子水平上的混合，使得这两种聚合物材料结合。
本发明的另一个实施方案涉及以下情况，其中，在与所述至少一层第一功能层(103)相反的一侧，所述至少一层金属层(101)被至少一层第二功能层(105)覆盖。
在这个实施方案中，提供了一种聚合物/金属/聚合物夹层结构作为层压组件(1)。这使得例如可以应用另一聚合物组件(3)到背面。
在另一种更进一步的发展中，所述至少一层金属层(101)与所述至少一层第一功能层(103)和/或所述至少一层第二功能层(105)以物质锁固方式接触。
用语“物质锁固”描述了一种结合，在这种结合中连接的部件通过原子力或分子力结合到一起。同时，物质锁固结合只有通过破坏结合本身才能分开。物质锁固结合可以通过例如软钎焊、焊接、胶粘或硫化的方式得到。
在该特别的实施方案中，提供了一种在所述至少一层金属层(101)和所述至少一层第一功能层(103)和/或至少一层第二功能层(105)之间的中间层，以增强接触，从而导致了物质锁固的特性。以这种方式构成的层压组件(1)能够用例如深拉伸等公知工艺进行加工，而不会出现第一或第二功能层(103、105)与金属层(101)的脱层。
在所述至少一层金属层(101)和所述至少一层第一功能层(103)之间和/或在所述至少一层金属层和所述至少一层第二功能层(105)之间的中间层可以由聚丙烯酸和/或丙烯酸共聚物和/或顺丁烯二酸共聚物形成。
在本发明的一个尤为特别的实施方案中，至少一层第一功能层(103)和/或聚合物组件(3)包括至少一种聚酰胺。其中，第一功能层(103)和聚合物组件(3)可能包括不同的聚酰胺。
所述至少一种聚酰胺可以从包括PA6、PA66、PA6/66、PA66/6、PA6T/6、PA6.10、PA6.12、PA12；PA9T、PA6I/6T、PA6T/6I、PA6/6.36或其组合的组中选择。功能层(103)和/或聚合物组件(3)也可包含有乙烯、丙烯和/或α-聚烯烃和/或丙烯酸酯和/或丙烯酸和/或顺丁烯二酸酐的均聚物或共聚物。这些共聚物可用顺丁烯二酸酐接枝。
在该实施方案的一个特定的进一步发展中，所述至少一层第一功能层(103)至少部分地包括一种激光吸收填充材料(107)。激光吸收填充材料(107)能够作为颗粒分布在第一功能层(103)中至少在待与聚合物组件(3)结合的那些区域。合适的激光吸收填充材料(107)可选自炭黑、有机和/或无机颜料和染料。根据本发明适用的激光吸收填充材料(107)的概述可见于WO94/12352A1(参见第5页第10行至第7页第26行)。
在本发明的第二方面，上述问题通过前述的本发明方法可获得的一种金属-聚合物复合材料零件得到解决。
本发明的金属-聚合物复合材料零件通常具有与其制造方法相同的优点。
在第三方面，本发明涉及一种层压组件(1)，该层压组件(1)包括：
-至少一层金属层(101)，
-至少一层第一功能层(103)，其覆盖所述至少一层金属层(101)，
其中，所述至少一层第一功能层(103)至少部分地包括激光吸收填充材料(107)。
金属层(101)和至少一层第一功能层(103)已经在上文中详细定义，此处适用相同的定义。
通过本发明的层压组件(1)提供了一种半加工零件，其设计用于与类似的层压组件或聚合物组件连接，以构造复合材料零件。
在本发明的层压组件(1)的进一步发展中，在至少一层第一功能层(103)的相反一侧，至少一层第二功能层(105)覆盖所述至少一层金属层(101)。
通过该进一步发展，能够在层压组件(1)的两面结合聚合物组件(3)，从而构造出复杂的结构。
所述至少一层第一功能层(103)能够通过常规热塑生产工艺生产得到(例如通过浇铸压延机(casting calender))，然后可在金属或塑料表面被层压(通过卷材涂布线或热压机、间隔热压机、双带压机)。
在层压组件(1)的一个优选实施方案中，所述至少一层第一功能层(103)和/或所述至少一层第二功能层(105)包括聚酰胺。上文已经给出了详细说明，该说明在此处也适用。
对层压组件(1)来说，优选的是所述至少一层金属层(101)与所述至少一层第一功能层(103)和/或所述至少一层第二功能层(105)以物质锁固方式接触。
由于层间的结合是物质锁固的，本发明的层压组件(1)能够经受深拉伸而不脱层，这拓宽了其应用范围。
在层压组件(1)的一个特别的实施方案中，所述至少一层金属层(101)具有功能属性。从而，本发明层压组件(1)或包括本发明层压组件(1)的金属-聚合物复合材料零件能够具有功能。例如，功能属性可以包括EMI屏蔽(EMI：电磁干扰)、散热性和防磨性。
优选地，上述根据本发明的层压组件(1)可通过以下步骤得到：
i)提供至少一层金属层(101)，可选地，与粘合剂一起提供，
ii)加热所述至少一层金属层(101)，
iii)提供至少一层第一功能层(103)到经加热的至少一层金属层(101)上，优选地，使用挤出工艺进行，
iv)将所述至少一层第一功能层(103)与经加热的至少一层金属层(101)压合到一起，
v)获得层压组件(1)。
通过上述方法，金属和聚合物塑料层的层压组件(1)能够在现有的连续工艺中生产。功能层(103)能够作为辊压好的制品挤出，在必要时可以储存，然后可以通过卷材涂布线层压到金属层(101)的表面。
最后，本发明非常具体的一方面涉及一种复合材料组件(1000)，该复合材料组件(1000)包括：
-根据本发明和如前文所述的层压组件(1)，
-结合到所述至少一层第一功能层(103)的聚合物组件(3)，
-在所述至少一层第二功能层(105)上提供的额外组件(1001)，所述至少一层第二功能层(105)在所述至少一层第一功能层(103)的相反侧。
在本发明的该可选发展中，可以在金属层(101)的相反侧增加其他元件，可以是例如加固/加强筋或者其他功能层如聚合物发泡材料层。
进一步的目的、特点、优点和可能的应用由以下优选实施方案的说明得到，优选实施方案的图不构成对发明的限制。所有说明的和/或图描述的特征以自身或任何组合的方式构成本发明的主题，甚至独立于其在权利要求书中的概述或其引用关系。在图中：
图1描绘了根据本发明一个实施方案的层压组件(1)和聚合物组件(3)的示意图，
图2描绘了层压组件1和聚合物组件(3)之间的结合步骤的示意图，
图3描绘了根据本发明优选实施方案的金属聚合物复合材料零件的示意图，
图4描绘了表示本发明层压组件(1)的每焊缝线长度的拉断力[N/mm]的图表。
在图1下部描绘了根据本发明一个实施方案的层压组件1。金属层101的顶部覆盖有第一功能层103，底部覆盖有另一层第二聚合物材料105。层压组件1整体形成了三维结构，该三维结构如图1的横截面图所示。在该整体结构中形成了第一沟槽1a。
在图1上部展示了聚合物组件3，其同样体现为横截面图中所示的三维结构，该三维结构包括了第二沟槽3a。
图2中给出了具体结合步骤的示意图概述，其中层压组件1与聚合物组件3结合。在第一功能层103中，激光吸收填充材料至少分布在要与聚合物组件3结合的那些部分。聚合物组件3至少在其外部区域具有激光传输性，以使激光束L通过聚合物组件3的这些区域进行传输并击中激光吸收填充材料107。该激光吸收材料(107)吸收激光束L的能量并将其转化为热量。通过这些热量，第一功能层103的聚合物材料至少处于软化或甚至熔化状态，并至少软化或甚至熔化与之接触的聚合物组件3的聚合物材料。
在图3中描绘了图2的结合步骤的结果，其中聚合物材料3与层压组件1处于物质锁固结合状态，从而围合出了空腔5。
金属层101和第一功能层103在层压组件1中的比例能够在厚度和表面覆盖度两方面进行变化。材料类型或性质的设置与本发明金属-聚合物复合材料零件的功能和加工/结合方法有关。
金属层101尤其适用于成型性、机械性能、电磁性能和/或热传导/散热。
第一功能层103(以及聚合物组件3)适用于机械性能、激光吸收性、电磁性能、表面性能和/或耐化学性等等。
对于电子设备外壳的生产，下列层压制品的配置尤为重要：
-层压组件1的总厚度：0.06mm-4.0mm
其中金属层101具有0.01mm-2.0mm的厚度
第一功能层103具有0.05-1.0mm的厚度
-金属材料：铝合金，软深冲钢(DC)
-第一和第二功能层103、105位于金属层101的两面而层压。
根据本发明，层压组件1能够通过本领域技术人员知晓的所有方法进行生产。优选地，层压组件1通过连续方法制造。优选地，根据本发明的层压组件1的制造方法包括以下步骤：
I提供包含以下组分的聚合物组合物(PC)的第一功能层103：
Ia)至少一种聚酰胺和/或热塑性聚氨酯
Ib)可包含C2-C20烯烃，
II加热金属层101的第一板，
III压合通过步骤II得到的经加热的第一板和通过步骤I得到的第一功能层103，同时维持层压组件1。
上文提及的C2-C20烯烃特别地可包含乙烯和/或丙烯酸酯和/或丙烯酸和/或α-聚烯烃和/或顺丁烯二酸酐和/或苯乙烯和/或丙烯的均聚物或共聚物、丙烯的均聚物。均聚物和共聚物能够用0.1％-1.0％的顺丁烯二酸酐接枝。
对于根据本发明的方法中的聚合物组合物(PC)，先前提供聚合物组合物(PC)的第一功能层103的方法同样为本领域技术人员所知。优选地，在步骤I中的第一功能层103通过挤出工艺提供。
从聚合物组合物(PC)提供第一功能层103的合适的挤出工艺为本领域技术人员所知，有例如铸造工艺、压光工艺、吹塑工艺或多次吹塑工艺。
实施例
层压组件1的生产
将表1中所列的聚合物使用ZE 25A UXTI双螺旋挤出机以表1所示的量混合以形成圆柱形颗粒。然后从所述颗粒挤出第一功能层103。在挤出步骤中，添加如表2所列量的炭黑母料。第一功能层103具有表2标明的厚度和40cm的宽度。表1+2给出的量均为重量％。
P1：聚酰胺6(BASF SE的Ultramid B24N)
P2：PA6/6.36(BASF SE的Ultramid Flex F29)
Co1：Lucalen A2540 D(Basell)；乙烯/丙烯酸正丁酯共聚物
Co2：Exxelor 1801(Exxon Chemicals)；顺丁烯二酸酐接枝乙烯和丙烯共聚物
Co3：乙烯羧酸共聚物(BASF SE的Luwax EAS 5)
A1：Irganox B 1171 2X20Kg 4G
A2：滑石
R1：炭黑母料，30％于PA6中
Figure BDA0003949452540000121
表1
Figure BDA0003949452540000122
Figure BDA0003949452540000131
表2
然后，将表2中说明的第一功能层103与经预处理的金属层101按压到一起以形成层压组件1。层压组件1被切割至300mm x200mm的尺寸。
使用表3给出的温度和保持时间。制造层压组件1，其中金属层101简称为层101，功能层103简称为层103/1、103/2等等。
层压组件1的结构在表3中说明，其中层压组件1简称为层压件1/1、层压件1/2等等。
作为金属层101，使用了经Gardobond(磷酸水溶液和丙烯酸溶液，商品名ChemetalGmbH)预处理并具有250μm的厚度的镀锌钢。
层压组件1的制造如下所述。将第一功能层103的薄片1和薄片2(如果有的话)依次放置在金属层101上，然后在使用合适间隔物的热压机中在250℃下压制60秒。薄片1始终与金属层101直接接触。目标厚度通过使用合适的间隔物(薄片)确定，多余的聚合物在热压工艺后会被去除。
Figure BDA0003949452540000132
表3
将得到的层压组件1剪切成30mm x 60mm的条，然后通过激光轮廓焊接与玻璃纤维增强的PA6(BASF SE的Ultramid B3EG6 UN)结合到一起。玻璃纤维增强的PA6的测试样本通过注塑成型生产得到，其具有30mm x 60mm x 2mm的尺寸。
在图4中，描绘了表示根据本发明获得的层压组件1的每焊缝线长度的拉断力[N/mm]的图表。
激光焊接设备设置如下：
Figure BDA0003949452540000141
轮廓激光焊接以下列参数执行：
Figure BDA0003949452540000142
在没有透射部分的连接层，焦点直径dF约为2.7mm。
附图标记
1 层压组件
101 金属层
103 第一功能层
105 第二功能层
107 激光吸收填充材料
3 聚合物组件
5 空腔
L 激光束

Claims (15)

1.一种金属-聚合物复合材料零件的制造方法，所述方法包括以下步骤：
a)提供层压组件(1)，其中，所述层压组件(1)包含至少一层金属层(101)，所述金属层(101)被至少一层第一功能层(103)覆盖，
b)提供聚合物组件(3)，
c)使所述聚合物组件(3)与所述层压组件(1)的所述至少一层第一功能层(103)接触，
d)通过物理处理使所述聚合物组件(3)结合至所述至少一层第一功能层(103)，
e)获得所述金属-聚合物复合材料零件。
2.根据权利要求1所述的方法，其中所述物理处理包括激光透射焊接、超声波焊接、摩擦焊接和/或热熔结合。
3.根据权利要求1或2所述的方法，其中所述聚合物组件(3)的材料至少部分地具有半透明性，特别是至少部分地可激光透射，并且所述物理处理包括激光透射焊接。
4.根据权利要求3所述的方法，其中所述层压组件(1)至少部分地表现出激光吸收性。
5.根据权利要求1至4任一项所述的方法，其中在步骤d)形成所述层压组件(1)和所述聚合物组件(3)之间的结合，所述结合至少部分地为物质锁固的。
6.根据权利要求1至5任一项所述的方法，其中在所述至少一层第一功能层(103)的相反侧，所述层压组件(1)的所述至少一层金属层(101)被至少一层第二功能层(105)覆盖。
7.根据权利要求1至6任一项所述的方法，其中所述至少一层金属层(101)与所述至少一层第一功能层(103)和/或所述至少一层第二功能层(105)以物质锁固方式接触。
8.根据权利要求1至7任一项所述的方法，其中所述至少一层第一功能层(103)和/或所述聚合物组件(3)包括至少一种聚酰胺。
9.根据权利要求1至8任一项所述的方法，其中所述至少一层第一功能层(103)至少部分地包括一种激光吸收填充材料(107)。
10.根据权利要求1至9任一项所述的方法可获得的金属-聚合物复合材料零件。
11.层压组件(1)，包括：
-至少一层金属层(101)和
-至少一层第一功能层(103)，所述至少一层第一功能层(103)覆盖所述至少一层金属层(101)，
其中所述至少一层第一功能层(103)至少部分地包括一种激光吸收填充材料(107)。
12.根据权利要求11所述的层压组件(1)，进一步包括至少一层第二功能层(105)，其在所述至少一层第一功能层(103)的相反侧覆盖所述至少一层金属层(101)。
13.根据权利要求11或12所述的层压组件(1)，其中所述至少一层第一功能层(103)和/或所述至少一层第二功能层(105)包括聚酰胺。
14.根据权利要求11至13任一项所述的层压组件(1)，其中所述至少一层金属层(101)表现出功能性。
15.复合组件(1000)，包括：
-根据权利要求12至14任一项所述的层压组件(1)，
-聚合物组件(3)，所述聚合物组件(3)结合至所述至少一层第一功能层(103)，
-附加组件(1001)，位于所述至少一层第二功能层(105)上与所述至少一层第一功能层(103)相反的一侧。
CN202180036107.XA 2020-05-19 2021-05-17 一种金属-聚合物复合零件及其制造方法 Pending CN115666908A (zh)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP20175452 2020-05-19
EP20175452.0 2020-05-19
PCT/EP2021/063011 WO2021233837A1 (en) 2020-05-19 2021-05-17 Method for manufacturing a metal-polymer hybrid part and metal-polymer hybrid part

Publications (1)

Publication Number Publication Date
CN115666908A true CN115666908A (zh) 2023-01-31

Family

ID=70779513

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202180036107.XA Pending CN115666908A (zh) 2020-05-19 2021-05-17 一种金属-聚合物复合零件及其制造方法

Country Status (4)

Country Link
US (1) US20230090894A1 (zh)
EP (1) EP4153404A1 (zh)
CN (1) CN115666908A (zh)
WO (1) WO2021233837A1 (zh)

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL9202096A (nl) 1992-12-02 1993-04-01 Dsm Nv Polymeersamenstelling, bevattende een polymeer en tenminste een stralingsgevoelig bestanddeel.
DE10361096A1 (de) 2003-12-22 2005-07-21 Robert Bosch Gmbh Bauteil und Verfahren zum Herstellen eines Bauteils
DE102004045402A1 (de) 2004-09-18 2006-03-23 Volkswagen Ag Bauteil für ein Kraftfahrzeug, Verfahren zu dessen Herstellung und Verwendung desselben
JP4714948B2 (ja) * 2006-10-05 2011-07-06 岡山県 レーザー接合用中間部材及びそれを用いた接合方法
JP2009119807A (ja) * 2007-11-19 2009-06-04 Dainippon Printing Co Ltd レーザー融着性積層材、レーザー融着方法および包装体
CN108407307A (zh) * 2012-07-05 2018-08-17 旭化成株式会社 焊接方法及焊接体
WO2019069840A1 (ja) * 2017-10-03 2019-04-11 三菱エンジニアリングプラスチックス株式会社 金属樹脂複合体および金属樹脂複合体の製造方法
DE102018207205A1 (de) 2018-05-09 2019-11-14 Thyssenkrupp Ag Hybrides Stahl-Kunststoffgehäuse für Leistungselektronik

Also Published As

Publication number Publication date
US20230090894A1 (en) 2023-03-23
EP4153404A1 (en) 2023-03-29
WO2021233837A1 (en) 2021-11-25

Similar Documents

Publication Publication Date Title
US20230192197A1 (en) Method of making a laminate, an energy absorbing device, an energy absorbing device composition, and a forming tool
JP6717321B2 (ja) 積層パネル及びその成形品の製造方法
US20180126700A1 (en) Fiber-containing polymeric materials and methods thereof
Vaidya et al. Processing of fibre reinforced thermoplastic composites
US20200139642A1 (en) Glass and carbon fiber composites and uses thereof
KR20140141583A (ko) 접합 부재의 제조 방법 및 접합 부재
GB2528668A (en) Method of Manufacturing A Structural Panel For An Engineering Structure
KR20160112950A (ko) 수지 접합체, 수지 접합체의 제조 방법 및 차량용 구조체
CN106687271B (zh) 制备具有集成增强结构的多壳复合材料构件的方法以及由其制得的多壳复合材料构件
CN115666908A (zh) 一种金属-聚合物复合零件及其制造方法
JP5891303B2 (ja) 金属樹脂成形品の製造方法
KR20200007854A (ko) 중합체 금속 하이브리드 물품
CN108290402B (zh) 复合成型体及其制造方法
US20230173794A1 (en) Polymer foam laminate structure
CA2801886C (en) Method of making automotive body parts
MXPA04000904A (es) Material laminado compuesto de polimero.
JP2018130854A (ja) 樹脂成形品の製造方法
JP2022151711A (ja) 複合成形体およびその製造方法
WO2024062103A1 (en) Process for producing a composite component comprising at least one metal layer and one polymer layer
EP3444103A1 (en) Method for manufacturing bonded body

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination