JP2017019189A - Method for producing composite molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a composite molding formed of a metal molding and a thermoplastic molding which dispenses with insert molding.SOLUTION: There is provided a method for producing a composite molding 1 formed by joining a metal molding 10 and a thermoplastic resin molding 20 which includes the steps of: roughening a joint surface 12 between the metal molding 10 and the thermoplastic resin molding 20; heating the roughened joint surface 12 of the metal molding 20 to a temperature equal to or higher than 50°C from a thermal deformation temperature (ISO 75 and load of 1.8 MPa) of a thermoplastic resin constituting the thermoplastic resin molding 20; and bonding the roughened joint surface 12 of the metal molding 10 and the thermoplastic resin molding 20, wherein the step of roughening the joint surface 12 of the metal molding 10 is a step of irradiating the joint surface 12 with a laser beam and roughening the joint surface 12.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a composite molded body comprising a metal molded body and a thermoplastic resin molded body.

From the viewpoint of reducing the weight of various parts, resin molded bodies are used as metal substitutes, but it is often difficult to substitute all metal parts with resin. In such a case, it is conceivable to manufacture a new composite part by joining and integrating the metal molded body and the resin molded body.
The inventions of Patent Documents 1 and 2 are known as methods for joining and integrating a metal molded body and a resin molded body with an industrially advantageous method and with high bonding strength.

In the invention of Patent Document 1, after the surface of the metal molded body is roughened by irradiating the continuous wave laser, insert molding or the like is performed in a state where the surface of the metal molded body is placed in a mold. In this method, a composite molded body of a metal molded body and a resin molded body is manufactured.
In the invention of Patent Document 2, after the surface of the metal molded body is roughened by irradiating a pulse wave laser, insert molding or the like is performed in a state where the surface of the metal molded body is placed in a mold. In this method, a composite molded body of a metal molded body and a resin molded body is manufactured.

Japanese Patent No. 5701414 JP2013-52669A

  This invention makes it a subject to provide the manufacturing method of the composite molded object which integrates, without using insert molding like the said prior art, when joining and integrating a metal molded object and a thermoplastic resin molded object. .

The present invention is a method for producing a composite molded body in which a metal molded body and a thermoplastic resin molded body are joined,
A step of roughening the joint surface of the metal molded body with the thermoplastic resin molded body,
Heating the roughened joint surface of the metal molded body so that the thermal deformation temperature (ISO75, load 1.8 MPa) of the thermoplastic resin constituting the thermoplastic resin molded body is 50 ° C. or higher;
Provided is a method for producing a composite molded body, comprising a step of pressure-bonding the roughened joint surface of the metal molded body and the thermoplastic resin molded body.

  According to the manufacturing method of the present invention, the insert molding step of the conventional manufacturing method of the composite molded body is not required, and therefore the thermoplastic resin molded body to be joined to the metal molded body has a desired shape and a desired appearance (pattern) in advance. In addition to being able to use, the selection range of the shape and size of the metal molded body is widened.

Explanatory drawing of the manufacturing method of the composite molded object of this invention. The perspective view of the aluminum plate used in the Example. In the manufacturing method of the composite molded object of this invention, explanatory drawing of the irradiation method when implementing continuous wave laser irradiation by a roughening process.

The method for producing the composite molded body of the present invention will be described with reference to FIG.
As shown in FIGS. 1A and 1B, in the first step, the joint surface 12 of the metal molded body 10 with the thermoplastic resin molded body 20 is roughened.

The metal of the metal molded body 10 is not particularly limited, and can be appropriately selected from known metals according to the application, but is sufficiently higher than the thermal deformation temperature of the thermoplastic resin constituting the thermoplastic resin molded body 20. It has a high melting point.
Examples of the metal of the metal molded body 10 include those selected from cermets such as iron, various stainless steels, aluminum, zinc, titanium, copper, magnesium and alloys containing them, tungsten carbide, chromium carbide, and the like. It can also be applied to those subjected to surface treatment such as alumite treatment and plating treatment on the above metal.
The shape of the metal molded body 10 is not particularly limited, and can be selected according to the application of the composite molded body, and can be selected from a plane, a curved surface, a combination of a plane and a curved surface, and the like.
The size of the metal molded body 10 is not particularly limited, and can be selected according to the use of the composite molded body. For example, an existing fixed metal molded body is an application target.

The surface roughening method of the joint surface 12 is not particularly limited, and a known method such as continuous wave laser irradiation, pulse wave laser irradiation, etching, sand blasting, or cutting can be applied. A roughening method by irradiation with a pulsed laser is preferred.
When the bonding surface 12 of the metal molded body 10 is roughened by irradiation with a continuous wave laser, as described in Patent Document 1, a continuous wave laser is used for the bonded surface of the metal molded body to 2000 mm / sec. A method of continuously irradiating laser light at the above irradiation speed can be applied.
When the joining surface 12 of the metal molded body 10 is roughened by irradiation with a pulse wave laser, the laser scanning method described in Patent Document 2 can be applied.

When the joint surface 12 of the metal molded body 10 is roughened by irradiation with a continuous wave laser, it can be performed under the following irradiation conditions.
The irradiation speed of the continuous wave laser is preferably 2000 to 20,000 mm / sec, more preferably 2,000 to 18,000 mm / sec, and further preferably 2,000 to 15,000 mm / sec.
The output is preferably 4 to 4000 W, more preferably 50 to 2500 W, further preferably 100 to 2000 W, and further preferably 250 to 2000 W.
The beam diameter (spot diameter) is preferably 5 to 200 μm, more preferably 5 to 100 μm, and still more preferably 10 to 100 μm.
Furthermore, the preferable range of the combination of the output and the spot diameter can be selected from the energy density E1 (W / μm ² ) obtained from the laser output and the laser irradiation spot area (π · [spot diameter / 2] ² ).
Energy density E1 (W / μm ²⁾ is preferably from 0.1 W / [mu] m ² or more, 0.2~10W / μm ² is more preferable.
When the energy density E1 (W / μm ² ) is the same, the larger the output (W), the larger the spot area (μm ² ) can be laser-irradiated, so the processing speed (laser irradiation per ^second ) (Area; mm ² / sec) is increased, and the processing time can be shortened.
The wavelength is preferably from 300 to 1200 nm, more preferably from 500 to 1200 nm.
The focal position is preferably −10 to +10 mm, more preferably −6 to +6 mm.

  A known continuous wave laser can be used, for example, YVO4 laser, fiber laser (preferably single mode fiber laser), excimer laser, carbon dioxide laser, ultraviolet laser, YAG laser, semiconductor laser, glass laser, ruby. Lasers, He—Ne lasers, nitrogen lasers, chelate lasers, and dye lasers can be used. Among these, since the energy density is increased, a fiber laser is preferable, and a single mode fiber laser is particularly preferable.

When a single straight line is formed by irradiation with a continuous wave laser, the irradiation may be performed once or repeated a plurality of times.
When repeatedly irradiating a single straight line, bidirectional irradiation and unidirectional irradiation can be selected.
When forming one line (groove), bidirectional radiation irradiates a continuous wave laser from the first end of the line (groove) to the second end, and then from the second end to the first end. In this method, the continuous wave laser is irradiated, and thereafter, the continuous wave laser is repeatedly irradiated from the first end to the second end and from the second end to the first end.
Unidirectional irradiation is a method of repeating unidirectional continuous wave laser irradiation from the first end to the second end.

The number of repetitions (passes) of continuous wave laser irradiation can be adjusted according to the roughened state of the bonding surface 12.
The roughened bonding surface is in a state in which holes and grooves as shown in FIGS. 7 and 8 of Patent Document 1 and SEM photographs of Examples are formed. The depth of the formed hole or groove is in the range of about 50 to 500 μm from the bonding surface 12.
Further, at the time of laser irradiation, an assist gas can be injected as required for the purpose of preventing metal oxidation and improving processing efficiency (reducing processing time).

Next, in the second step (FIG. 1 (c)), the roughened joint surface 12 of the metal molded body 10 has a heat distortion temperature (ISO75, load 1.8) of the thermoplastic resin constituting the thermoplastic resin molded body. To 50 ° C. or higher.
The heating method can be selected according to the size and shape of the metal molded body 10.
If the metal molded body 10 is small or thin, the metal molded body 10 itself can be placed in an oven and heated as a whole, or the metal molded body 10 can be placed on a hot plate and heated. .
If the metal molded body 10 is large or long and cannot be heated in an oven, it can be heated around the joint surface 12 roughened with a gas burner or the like.
The heating temperature may be 50 ° C. or more (if the heat deformation temperature is 100 ° C., 150 ° C. or more) from the heat deformation temperature of the thermoplastic resin, but is preferably 50 to 200 ° C. higher than the heat deformation temperature. Heat to a temperature range. The above temperature range is preferable because the bonding strength between the metal molded body and the thermoplastic resin molded body is increased and the shape of the thermoplastic resin molded body can be maintained.
In FIG.1 (c), the metal forming body 10 is placed and heated on the lower press board 50 in which the heating apparatus was incorporated.

Next, in the third step, as shown in FIGS. 1D and 1E, the roughened joint surface 12 of the metal molded body 10 heated in the previous step and the thermoplastic resin molded product 20 The joining surface 22 is crimped.
As a crimping method, for example,
A state in which the metal molded body 10 is fixed on a work table (preferably a work table having a heating device) so that the bonding surface 12 faces upward, and the bonding surface 22 of the thermoplastic resin molded body 20 is aligned with the bonding surface 12. Then, a method of pressing from the thermoplastic resin molded body 20 side,
In a state where the joint surface 12 of the metal molded body 10 and the joint surface 22 of the thermoplastic resin molded body 20 are combined, the metal molded body 10 on the lower press (preferably a press having a heating device) side and the thermoplastic resin on the upper press side. A method of pressing from both of the molded bodies 20,
Can be applied.
In addition, it is also possible to apply a method of pressing from one or both in a state where the metal molded body 10 and the thermoplastic resin molded body 20 are arranged to face each other in the horizontal direction.
In FIG. 1 (d), the metal molded body 10 is placed on the lower press plate 50 heated to a predetermined temperature, the metal molded body 10 is heated to a predetermined temperature, and then a thermoplastic resin molding is formed on the joining surface 12. After the body 20 is placed, in FIG. 1E, pressure is applied from above and below with the lower press plate 50 on the metal molded body 10 side and the upper press plate 51 on the thermoplastic resin molded body 20 side.

When the bonding surface 22 of the thermoplastic resin molded body 20 is pressure-bonded to the bonded surface 12 of the metal molded body 10 thus heated, the thermoplastic resin of the bonding surface 22 is melted by the heat of the bonding surface 12.
Since the joining surface 12 and the joining surface 22 are pressure-bonded, the molten thermoplastic resin enters the inside of the hole or groove formed in the joining surface 12 of the metal molded body 10.
Then, by applying a method of cooling by releasing the pressure-bonded state or a method of cooling while maintaining the pressure-bonded state, the thermoplastic resin that has entered the inside of the hole or groove of the joint surface 12 of the metal molded body 10 is obtained. In order to solidify, the metal molded body 10 and the thermoplastic resin molded body 20 are integrated with high joint strength.
When applying the method of cooling while maintaining the pressure-bonded state, in addition to the method of stopping the heating by the lower press plate 50 in the state of FIG. Cooling can also be performed using a cooling device 51 as a built-in device.

The thermoplastic resin used in the thermoplastic resin molded body 20 can be appropriately selected from known thermoplastic resins depending on the application.
For example, cellulose ester such as cellulose acetate (including a plasticizer), polyamide resin (aliphatic polyamide such as PA6 and PA66, aromatic polyamide), polystyrene, ABS resin, co-polymer containing styrene units such as AS resin Polymers, polyethylene, copolymers containing ethylene units, polypropylene, copolymers containing propylene units, other polyolefins, polyvinyl chloride, polyvinylidene chloride, polycarbonate resins, acrylic resins, methacrylic resins, polyester resins, Examples thereof include polyacetal resins and polyphenylene sulfide resins.

  Moreover, it can replace with a thermoplastic resin and can also use a thermoplastic elastomer. Examples of the thermoplastic elastomer include styrene elastomers, vinyl chloride elastomers, olefin elastomers, urethane elastomers, polyester elastomers, nitrile elastomers, and polyamide elastomers.

  These thermoplastic resins and thermoplastic elastomers can be blended with known fibrous fillers such as carbon fibers, inorganic fibers, metal fibers, and organic fibers, and known additives for resins.

As the thermoplastic resin molded body 20, one having a desired pattern on at least the surface (the surface excluding the joining surface 22) can be used depending on the application.
The said pattern may be printed on the surface of the thermoplastic resin molding 20, and the same pattern may be formed from the inside to the surface.
In addition to various patterns, the patterns include various characters, figures, pictures, cartoons, photographs, color classification (for example, color classification with gradation), and combinations thereof.
In the inventions of Patent Documents 1 and 2 described above, the metal molded body and the resin molded body are joined and integrated by an insert molding method or a compression molding method (a compression molding method using resin pellets). Patterns cannot be formed on the body.
In the manufacturing method of the present invention, since the metal molded body 10 and the thermoplastic resin molded body 20 are integrated by pressure bonding, a desired pattern (pattern that appears in the appearance of the final product) of the thermoplastic resin molded body 20 is formed in advance. Therefore, the use of the obtained composite molded body can be selected from a wider range.

Examples 1-6
(First step: FIGS. 1A and 1B)
An aluminum (A5052) plate 10 (4 mm long, 10 mm wide, 50 mm long) shown in FIG. 2 is placed on a work table (steel plate), and a continuous wave laser is irradiated under the conditions shown in Table 1 using the apparatus shown in FIG. Thus, the joint surface 12 (4 × 10 mm) was roughened.
The metal molded body 10 shown in FIG. 1 is not limited to the aluminum plate used in the examples, so the dimensions of the metal molded body 10 shown in FIG. 1 and the aluminum plate shown in FIG. 2 do not match. .

Laser irradiation device (Figure 2)
100: Single-mode fiber laser tip
101: Optical head
102: fc lens
103: fθ lens
104: protective lens d1: fiber diameter d2: spit diameter f1: focal length of fc lens f2: focal length of fθ lens

(Single mode fiber laser)
Oscillator: IPG-Yb fiber, YLR-300-SM (IPG)
Optical head: LXD30 + ARGES SQUIRREL (fc = 80mm / fθ = 100mm or fc = 80mm / fθ = 163mm)
Output: 274W
Fiber diameter: 9μm
Minimum spot diameter: 11 μm
Spot area: 9.93516 × 10 ^-7 cm ²
Maximum traveling speed: 13330mm / sec

Examples 1, 2, 4 to 6 are focused on the surface of the metal molded body 10 (the defocus distance is ± 0 mm), and Example 3 is focused on the inside of the metal molded body 10. (Defocus distance is -0.05mm).
In Examples 1 to 4, a lens combination of fc = 80 mm / fθ = 100 mm was used, and in Examples 5 and 6, a lens combination of fc = 80 mm / fθ = 163 mm was used.
In Example 4, laser irradiation was performed using a nozzle (nozzle shape: 7 mm × 3 mm oval) while supplying compressed air (pressure 0.3 MPa) as an assist gas.

(Second step: FIG. 1 (c))
A metal molded body is placed on a press plate heated to 180 ° C. equipped with a heating device so that the roughened bonding surface 12 faces up, and the bonding surface 12 becomes 180 ° C. under the conditions shown in Table 2. Until heated.

(Third step: FIGS. 1D and 1E)
Roughened joint surface 12 of metal molded body 10 and cellulose acetate resin [including cellulose acetate and plasticizer, etc .; product name; Celbrene EC210, manufactured by Daicel Polymer Co., Ltd., heat distortion temperature (ISO75, load 1.8 MPa) ) 66 ° C.] from a patterned sheet prepared by multi-color extrusion molding, with the joint surface 22 of the plate (4 mm long, 10 mm wide, 50 mm long) 20 produced together, a press pressure of 1 MPa, a press time of 60 seconds Was pressed from above and below.
In addition, although the press operation of the metal molded body and the cellulose acetate-based resin plate was performed at room temperature (20 to 25 ° C.), since the pressing time is 60 seconds, the metal molded body is heated by the cellulose acetate resin until the end of pressing. It is obvious that the temperature is 50 ° C. or more higher than the deformation temperature.
Thereafter, heating was stopped in the pressed state, and the mixture was naturally cooled to room temperature to obtain a composite molded body 1. The pattern of the cellulose resin plate of the composite molded body was almost the same as that before press molding with almost no change.

It was confirmed that the obtained composite molded body was in close contact with the surface of the metal molded body.
The fact that the metal molded body and the thermoplastic resin molded body are bonded with high bonding strength is obvious from the tensile bonding strength shown in Examples 10 to 15 (Table 3) to which the compression molding method of Patent Document 1 is applied. It is.

By applying the method for producing a composite molded body of the present invention to a known metal molded body, a composite molded body of a metal molded body and a thermoplastic resin molded body can be obtained.
For example, metal molding used in daily necessities, cooking utensils, sports equipment, furniture, OA equipment, communication equipment, various electrical products, bicycle parts, motorcycle parts, automobile parts such as automobiles, interior parts, exterior parts, building materials, etc. By applying to a body, it can be set as a composite molded body with a thermoplastic resin molded body.
In addition, the method for producing a composite molded body of the present invention is applied to a large fixed object such as a metal molded body (wall, beam, column, etc.) used in an existing or under construction building, The surface of the metal molded body is covered with a patterned thermoplastic resin sheet without using an adhesive, or a patterned thermoplastic resin molded article (for example, a product is hung on a metal molded article without using screws, etc.) Hooks, curtain rails, plates (shelves), mesh baskets, bars, frames, pillars) can be fixed.

1 Composite Molded Body 10 Metal Molded Body 12 Joint Surface (Roughened Joint Surface)
20 Thermoplastic resin molding 22 Bonding surface

Claims (4)

A method for producing a composite molded body in which a metal molded body and a thermoplastic resin molded body are joined,
A step of roughening the joint surface of the metal molded body with the thermoplastic resin molded body,
Heating the roughened joint surface of the metal molded body so that the thermal deformation temperature (ISO75, load 1.8 MPa) of the thermoplastic resin constituting the thermoplastic resin molded body is 50 ° C. or higher;
The manufacturing method of a composite molded object which has the process of crimping | bonding the roughened joint surface of the said metal molded object, and the said thermoplastic resin molded object.   The method for producing a composite molded body according to claim 1, wherein the step of roughening the joint surface of the metal molded body is a step of roughening the joint surface by irradiating a laser beam. The step of roughening the joint surface of the metal formed body is a step of roughening by irradiating the joint surface with continuous wave laser light,
The step of irradiating the continuous wave laser beam comprises:
The irradiation speed of the continuous wave laser is 2,000-15,000 mm / sec,
The laser output is 250 to 2000 W, the laser beam diameter (spot diameter) is 10 to 100 μm,
The laser power and spot area energy density obtained from ([pi · [spot diameter / 2] ^{2) E1 (W / μm 2} ) is continuously irradiated with the laser beam to be in the range of 0.2～10W / [mu] m ² The manufacturing method of the composite molded object of Claim 1 or 2 which is a process.   The method for producing a composite molded body according to any one of claims 1 to 3, wherein the thermoplastic resin molded body has a desired pattern at least on a surface thereof.

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