JP2010194762A - Method for joining thermoplastic resin to metallic adherend and method for manufacturing housing member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for joining a thermoplastic resin to a metallic adherend, in which the thermoplastic resin can be tightly joined to the metallic adherend regardless of a shape of a joining surface of the metallic adherend, the time required for joining can be shortened, joining is not restricted by the shape and alignment of the joining surface and further a series of processes for molding the thermoplastic resin and joining it to the metallic adherend can be simplified, and to provide a method for manufacturing a housing member. <P>SOLUTION: The method for joining the thermoplastic resin to the metallic adherend includes a process for forming a self-adhesive layer 3 at the joining surface 2 of the metallic adherend 1 to the thermoplastic resin 4 and a process for bringing the thermally molten thermoplastic resin 4 into contact with the self-adhesive layer 3 and then solidifying it. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for joining a metal adherend and a thermoplastic resin and a method for producing a housing member.

  2. Description of the Related Art Conventionally, a metal member and a thermoplastic resin bonded to each other are used as a housing member that constitutes building materials and equipment installed in a house. When joining a metal adherend and a thermoplastic resin in the manufacture of a housing member, for example, using a molded product of a thermoplastic resin molded into a desired shape in advance, the molded product of the thermoplastic resin and the metal A method of adhering to an adherend is used.

  However, in the method of bonding a metal adherend and a thermoplastic resin molded product, accuracy is required for the shape and alignment of the joint surfaces of the metal adherend and the thermoplastic resin molded product. Furthermore, a multi-step process including a thermoplastic resin molding process and a bonding process between a metal adherend and a thermoplastic resin molded product is required.

  Conventionally, techniques described in Patent Document 1 and Patent Document 2 have been proposed as a method of joining a metal adherend and a resin. In Patent Document 1, a molded product of a polyolefin resin formed in advance is disposed on the adhesive layer side of a skin material in which a base layer of a transparent film, a metal thin film layer as a metal adherend, and an adhesive layer are laminated. Then, after the skin material is heated and softened, the skin material and the polyolefin resin are brought into contact with each other by bringing the adhesive layer side of the skin material into contact with the surface of the molded article of the polyolefin resin with the reduced pressure atmosphere of the skin material. The molded product is joined.

  However, since this technology uses a polyolefin resin molded product that has been molded into a desired shape in advance, in order to obtain the shape and alignment accuracy of the joint surface of the skin material and the molded product of the polyolefin resin, It is necessary to soften by heating and to apply special conditions under reduced pressure using a vacuum lamination device or the like.

  In Patent Document 2, a resin layer such as nylon is applied to an iron base material as a metal adherend by a fluid dipping method to form a coating layer, dried and placed in a mold, and then a thermoplastic resin. The coating layer by powder coating and the thermoplastic resin are thermally bonded by injection molding.

  However, this technique requires powder coating by a fluidized dipping method, which complicates the process and lacks versatility.

  Against this backdrop, further studies have been made in terms of bonding strength and process simplification in the bonding of a metal adherend and a thermoplastic resin in a housing member. A primer layer using chlorinated polypropylene is formed on the joint surface of the metal adherend to join the body and polypropylene resin, and then the molten thermoplastic resin is brought into contact with the primer layer and solidified by injection molding or the like. It is being considered to do.

JP 2006-224459 A JP-A-6-234163

  However, in this technique, after applying a primer to the joint surface of the metal adherend, it takes a long time, for example, several hours to cure the solvent and stabilize the coating film. In addition, when the flow of the molten resin is large as in the case of injection molding, the primer layer formed on the joining surface of the metal adherend may be washed away and the joining strength may be reduced. Furthermore, the organic solvent used at the time of application | coating of a primer may become restrictions in a work place or an installation surface.

  The present invention has been made in view of the circumstances as described above, and can adhere and bond the metal adherend and the thermoplastic resin regardless of the shape of the joining surface of the metal adherend. Metal that can shorten the time required for bonding, is not subject to restrictions on the shape and alignment of the bonding surface, and can further simplify the series of processes for molding thermoplastic resins and bonding to metal substrates It is an object of the present invention to provide a method for joining an adherend and a thermoplastic resin and a method for producing a housing member.

  The present invention is characterized by the following in order to solve the above problems.

  1stly, the joining method of the metal adherend of this invention and a thermoplastic resin is the process which forms an adhesion layer in the joining surface with the thermoplastic resin in a metal adherend, and the thermoplastic resin which carried out heat melting. And contacting the adhesive layer and then solidifying.

  Secondly, in the method for joining the first metal adherend and the thermoplastic resin, the hot-melt thermoplastic resin is formed in the adhesive layer in the mold at the time of injection molding, transfer molding, or compression molding. It is made to contact.

  Thirdly, in the method for joining the first or second metal adherend and the thermoplastic resin, the adhesive layer is made of a double-sided adhesive tape having an adhesive on both surfaces of the substrate.

  Fourth, in the method for joining the third metal adherend and the thermoplastic resin, the base material of the double-sided pressure-sensitive adhesive tape is a polymer foam.

  Fifth, in any one of the first to fourth metal adherends and the thermoplastic resin, the thermoplastic resin is a polyolefin resin.

  6thly, the manufacturing method of the housing member of this invention includes the process of joining the metal adherend which is a constituent material of a housing member, and a thermoplastic resin by any one of the said 1st thru | or 5th method. It is characterized by that.

  According to the first invention, since the adhesive layer is formed on the joining surface of the metal adherend with the thermoplastic resin, the metal adherend and the thermoplastic resin are in close contact with each other by the adhesive layer. Can be joined. And since curing is not required as in the case of primer application treatment, the time required for joining can be greatly shortened. Furthermore, by thermally melting the thermoplastic resin, regardless of the shape of the joining surface of the metal adherend, the thermoplastic resin can be adhered to the joining surface of the metal adherend via an adhesive layer. There are no restrictions on the shape and alignment of the joint surface.

  According to the second aspect of the invention, the metal adherend can be bonded to the thermoplastic resin simultaneously during injection molding, transfer molding, or compression molding, so that in addition to the effects of the first aspect of the invention. Compared to the case where the thermoplastic resin is pre-molded and then joined to the metal adherend, the process for molding the thermoplastic resin and joining the metal adherend is greatly simplified. can do.

  According to the third aspect of the invention, by forming the adhesive layer from a double-sided adhesive tape, in addition to the effects of the first and second aspects, the bonding strength between the metal adherend and the thermoplastic resin is increased. Can do.

  According to the fourth invention, the base material of the double-sided pressure-sensitive adhesive tape is a polymer foam, and in addition to the effects of the third invention, the metal adherend and the thermoplastic resin are peeled from the joint surface. Even when a load is applied in the direction, the stress is dispersed by the polymer foam. Therefore, the bonding strength between the metal adherend and the thermoplastic resin can be particularly increased.

  According to the fifth invention, by using a polyolefin resin such as polyethylene and polypropylene as the thermoplastic resin, in addition to the effects of the first to fourth inventions, a high versatility resin is used and the bonding strength is high. A joined body of the metal adherend and the thermoplastic resin can be obtained.

  According to the sixth aspect, since the metal adherend and the thermoplastic resin are joined by the first to fifth methods, the shape of the joining surface of the metal adherend according to the housing member Regardless of this, it is possible to obtain a housing member in which the metal adherend and the thermoplastic resin are in close contact with each other.

It is sectional drawing explaining embodiment of the joining method of the metal adherend and thermoplastic resin of this invention in order of a process. It is sectional drawing explaining another embodiment of the joining method of the metal adherend of this invention, and a thermoplastic resin.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a cross-sectional view illustrating an embodiment of a method for joining a metal adherend and a thermoplastic resin according to the present invention in the order of steps.

  In this embodiment, first, as shown in FIG. 1A, a metal adherend 1 is prepared. The metal adherend 1 can be used without particular limitation as long as it has a fixed shape having rigidity such as a plate shape, a square shape, and a curved shape.

  As a material of the metal adherend 1, various metal materials such as metals such as aluminum, copper and iron, and alloys thereof can be used without particular limitation. Moreover, the thin coating process may be given to the surface of the metal material.

  Next, an adhesive layer 3 is formed on the bonding surface 2 of the metal adherend 1 to the thermoplastic resin 4 as shown in FIG.

  The pressure-sensitive adhesive layer 3 is a layer having a pressure-sensitive adhesive. For example, the pressure-sensitive adhesive is a sheet-like pressure-sensitive adhesive formed in a thin uniform sheet, and a pressure-sensitive adhesive having a thin and uniform thickness is formed on both surfaces of a base material as a support. The formed double-sided pressure-sensitive adhesive tape or the like can be used as a material for forming the pressure-sensitive adhesive layer 3. For example, a commercial product in which these sheet-like pressure-sensitive adhesives and double-sided pressure-sensitive adhesive tapes are held between two release films can be used.

  As an adhesive used for the adhesion layer 3, an acrylic adhesive etc. are mentioned, for example.

  When forming the adhesive layer 3 on the bonding surface 2 of the metal adherend 1, for example, the release film on one side of the adhesive layer 3 held between the two release films is peeled off and exposed. One side of the pressure-sensitive adhesive layer 3 is brought into close contact with the metal adherend 1 and then the remaining release film is peeled off.

  When the adhesive layer 3 is comprised from a double-sided adhesive tape, the joining strength by joining with the metal adherend 1 and the thermoplastic resin 4 as shown in FIG.1 (c) can be improved. Examples of the base material of the double-sided pressure-sensitive adhesive tape include nonwoven fabrics, woven fabrics, polymer foams such as acrylic resin foams, polyurethane foams, and polyethylene foams. In particular, since the base material of the double-sided pressure-sensitive adhesive tape is a polymer foam, stress is dispersed by the polymer foam even when the joint surface 2 is subjected to a load in the peeling direction. Particularly, the bonding strength with the thermoplastic resin 4 can be increased.

  In addition, the aspect which arrange | positions the adhesion layer 3 in the joining surface 2 of the metal adherend 1 is the same as that of FIG.1 (b) and (c). It may be arranged in the entire surface of the bonding surface 2 or, if the bonding strength can be ensured, a plurality of adhesive layers 3 are arranged in the lateral direction along the surface of the bonding surface 2 of the metal adherend 1. The aspect arrange | positioned separately may be sufficient.

  Next, the hot-melt thermoplastic resin 4 is brought into contact with the adhesive layer 3 formed on the bonding surface 2 of the metal adherend 1 and then solidified. Thereby, as shown in FIG.1 (c), the metal adherend 1 and the thermoplastic resin 4 are joined.

  For example, at the time of molding by injection molding, transfer molding, or compression molding, the hot-melt thermoplastic resin 4 can be brought into contact with the adhesive layer 3 in the mold. By doing in this way, since the metal adherend 1 and the thermoplastic resin 4 can be simultaneously joined at the time of molding, the thermoplastic resin 4 is molded in advance and then joined to the metal adherend 1. Compared with the case where it performs, a series of processes for shaping | molding of the thermoplastic resin 4 and joining with the metal adherend 1 can be simplified greatly.

  As a mode in which the hot-melt thermoplastic resin 4 is brought into contact with the adhesive layer 3 formed on the bonding surface 2 of the metal adherend 1, in addition to the above-described method such as injection molding, for example, molding of the thermoplastic resin 4. The aspect which heat-melts and contacts only the part by the side of the joint surface 2 with the metal adherend 1 among the whole goods is mentioned.

  Although there is no restriction | limiting in particular as the thermoplastic resin 4, For example, by using polyolefin resin, such as polyethylene and a polypropylene, the metal adherend 1 and the thermoplastic resin 4 with high joint strength using resin with high versatility are used. And a joined body can be obtained.

  FIG. 2 is a cross-sectional view illustrating another embodiment of the method for joining a metal adherend and a thermoplastic resin of the present invention.

  In this embodiment, the metal adherend 1 having a curved joining surface 2 is used to form an adhesive layer 3 on the joining surface 2, and then heat-melting the thermoplastic resin 4 is used as the adhesive layer 3. The metal adherend 1 and the thermoplastic resin 4 are joined by bringing them into contact with and solidifying.

  As described above, even if the metal adherend 1 has a three-dimensional shape such as a curved surface shape, by melting the thermoplastic resin 4 by heat, the metal adherend 1 is made of metal regardless of the shape of the joining surface 2 of the metal adherend 1. The thermoplastic resin 4 can be bonded to the bonding surface 2 of the adherend 1 through the adhesive layer 3 and bonded. Therefore, the joining method of the present invention can be suitably applied to the manufacture of a housing member that constitutes building materials and equipment installed in a house, and the joining surface regardless of the shape of the metal adherend 1 corresponding to the housing member. The thermoplastic resin 4 can be brought into close contact with the adhesive layer 2 via the adhesive layer 3 and bonded.

EXAMPLES Hereinafter, although an Example demonstrates this invention in more detail, this invention is not limited to these Examples at all.
<Example 1>
Adhesive (made by KOKUYO S & T Co., Ltd., Dot Liner Pro Needs) using a thin coated aluminum plate (epoxy pre-coated aluminum plate) as a metal adherend ), Release the release film on one side, adhere the exposed adhesive surface to the joint surface of the aluminum plate with the polypropylene resin, and then peel off the remaining release film to form an adhesive layer made of an adhesive. Formed.

  The upper hot plate of the hot press was heated to 40 ° C. and the lower hot plate was heated to 300 ° C., and a polypropylene resin (manufactured by Daicel Chemical Industries, Ltd., PP-GF40-02) was placed on the lower hot plate and melted. Next, an aluminum plate with the joint surface facing downward was placed on the molten polypropylene resin, and compression molding was performed.

  With respect to the aluminum plate-polypropylene resin joined body thus obtained, the joining strength between the aluminum plate and the polypropylene resin was measured. The aluminum plate-polypropylene resin joined body was cut into a width of 10 mm and a length of 100 to 150 mm to prepare a test piece. A part of the polypropylene resin was peeled off at the joint surface using a cutter knife or the like, and the peeled polypropylene resin was pulled in a direction of 90 degrees with respect to the joint surface, and the average joint strength [N / cm] was measured. Note that the preparation of the test piece and the measurement of the bonding strength were performed 24 hours after the compression molding.

Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.
<Example 2>
Double-sided adhesive tape (5150, manufactured by Nitto Denko Corporation) held between two release films using a thin coated aluminum plate (epoxy precoated aluminum plate) as a metal adherend Double-sided pressure-sensitive adhesive tape by peeling the release film on one side of the material (PET non-woven fabric), bringing the exposed adhesive surface into intimate contact with the joining surface of the aluminum plate with the polypropylene resin, and then peeling off the remaining release film. An adhesive layer was formed.

  Thereafter, compression molding was performed under the same conditions as in Example 1 using a polypropylene resin (PP-GF40-02, manufactured by Daicel Chemical Industries, Ltd.) to obtain an aluminum plate-polypropylene resin joined body.

  About the obtained aluminum plate-polypropylene resin joined body, it carried out similarly to Example 1, and measured the joint strength of an aluminum plate and polypropylene resin.

Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.
<Example 3>
In Example 2, as a double-sided pressure-sensitive adhesive tape, Y-4932 (Sumitomo 3M Co., Ltd., base material: foamed acrylic resin) was used, and other than that, in the same manner as in Example 2, the aluminum plate was joined to the polypropylene resin. An adhesive layer made of double-sided adhesive tape was formed on the surface.

  Thereafter, compression molding was performed under the same conditions as in Example 1 using a polypropylene resin (PP-GF40-02, manufactured by Daicel Chemical Industries, Ltd.) to obtain an aluminum plate-polypropylene resin joined body.

  About the obtained aluminum plate-polypropylene resin joined body, it carried out similarly to Example 1, and measured the joint strength of an aluminum plate and polypropylene resin.

Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.
<Example 4>
In the same manner as in Example 3, an adhesive layer made of a double-sided adhesive tape was formed on the joint surface of the aluminum plate with the polypropylene resin.

  An aluminum plate is fixed inside the mold for injection molding with the joint surface with the polypropylene resin inside, and the polypropylene resin (PP-GF40-02, manufactured by Daicel Chemical Industries, Ltd.) is injected using an injection molding machine. Molded.

  About the obtained aluminum plate-polypropylene resin joined body, it carried out similarly to Example 1, and measured the joint strength of an aluminum plate and polypropylene resin.

Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.
<Comparative Example 1>
An aluminum plate-polypropylene resin joined body was obtained in the same manner as in Example 1 except that the adhesive layer was not formed on the joining surface of the aluminum plate with the polypropylene resin.

Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.
<Comparative example 2>
In Example 1, instead of forming an adhesive layer on the joining surface of the aluminum plate with the polypropylene resin, instead of this, a chlorinated polypropylene primer (F-7, manufactured by Toyo Kasei Kogyo Co., Ltd.) was used on the joining surface. The primer layer was formed by applying and curing at room temperature for 10 hours.

  Thereafter, compression molding was performed under the same conditions as in Example 1 using a polypropylene resin (PP-GF40-02, manufactured by Daicel Chemical Industries, Ltd.) to obtain an aluminum plate-polypropylene resin joined body.

  About the obtained aluminum plate-polypropylene resin joined body, it carried out similarly to Example 1, and measured the joint strength of an aluminum plate and polypropylene resin.

Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.
<Comparative Example 3>
In the same manner as in Comparative Example 2, a primer layer was formed on the aluminum plate bonded to the polypropylene resin, and then the aluminum plate was fixed in an injection molding mold with the polypropylene resin bonded surface inside, and then injected. Polypropylene resin (manufactured by Daicel Chemical Industries, PP-GF40-02) was injection molded using a molding machine.

  About the obtained aluminum plate-polypropylene resin joined body, it carried out similarly to Example 1, and measured the joint strength of an aluminum plate and polypropylene resin.

  Table 1 shows the bonding state between the aluminum plate and the polypropylene resin, and the measurement results of the bonding strength.

  From Table 1, in Comparative Example 1 in which compression molding was performed without forming an adhesive layer on the joining surface of the aluminum plate with the polypropylene resin, the polypropylene resin was peeled off from the aluminum plate, and the aluminum plate and the polypropylene resin were joined. I could not.

  Moreover, in Comparative Examples 2 and 3 in which a primer layer was formed instead of the adhesive layer, the aluminum plate and the polypropylene resin could be bonded, but for about 10 hours for solvent drying and coating stabilization. Curing was necessary.

  On the other hand, in Examples 1 to 4 in which the adhesive layer was formed on the joint surface of the aluminum plate with the polypropylene resin, the aluminum plate and the polypropylene resin adhered to the adhesive layer without performing curing after forming the adhesive layer. These were able to be joined.

  In Example 2 using a double-sided adhesive tape for the adhesive layer, the bonding strength was further improved as compared to Example 1 in which an adhesive layer made of an adhesive was formed.

  In particular, in Example 3 in which the polymer foam was used as the base material of the double-sided pressure-sensitive adhesive tape, the stress applied to the peeling was dispersed by the polymer foam, so that the bonding strength was greatly improved.

  In Example 4 where the aluminum plate and the polypropylene resin were joined by injection molding, the joining strength was the same level as in the compression molding of Example 3. In Examples 2 to 4, excellent bonding strength equal to or higher than that of Comparative Examples 2 and 3 in which curing was performed after forming the primer layer was obtained.

  In Comparative Example 3 in which the aluminum plate and the polypropylene resin were joined by injection molding, a non-joined portion that was considered to be due to the movement of the primer accompanying the flow of the molten resin on the joining surface was seen, and the average joining strength was Compared with the case of compression molding in Comparative Example 2, it decreased.

DESCRIPTION OF SYMBOLS 1 Metal adherend 2 Joining surface 3 Adhesive layer 4 Thermoplastic resin

Claims (6)

  A method for joining a metal adherend and a thermoplastic resin, the step of forming an adhesive layer on the joining surface of the metal adherend with the thermoplastic resin, and contacting the heat-melted thermoplastic resin with the adhesive layer And then solidifying the metal adherend and the thermoplastic resin.   The metal adherend and the thermoplastic resin according to claim 1, wherein the thermoplastic resin melted by heating is brought into contact with the adhesive layer in the mold at the time of molding by injection molding, transfer molding, or compression molding. Joining method.   The method for joining a metal adherend and a thermoplastic resin according to claim 1 or 2, wherein the adhesive layer comprises a double-sided adhesive tape having an adhesive on both surfaces of the substrate.   The method for joining a metal adherend and a thermoplastic resin according to claim 3, wherein the base material of the double-sided pressure-sensitive adhesive tape is a polymer foam.   The method for joining a metal adherend and a thermoplastic resin according to any one of claims 1 to 4, wherein the thermoplastic resin is a polyolefin resin.   A method for producing a housing member comprising the step of joining a metal adherend that is a constituent material of the housing member and a thermoplastic resin by the method according to any one of claims 1 to 5.

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