JP4753756B2 - Resin-ceramic bonded body and manufacturing method thereof - Google Patents

Description

  The present invention relates to a joined body of a ceramic member and a resin member. In particular, a highly porous dimensional accuracy is obtained by using a ceramic member having a partially porous joint region and impregnating the porous region with a resin. The present invention relates to a required resin-ceramic bonded body.

  Conventionally, as a method of assembling a ceramic member and a resin member, a technique of integrating a ceramic member by resin molding is known. For example, a resin molded product in which a resin portion made of a resin molding material is bonded to the outer peripheral surface of a ceramic member is known. Then, by providing a plurality of chippings and chipping recesses at locations where the ceramic member comes into contact with the resin member, and providing a dense layer with pores having a mean particle size equal to or larger than the filler average particle size of the ceramic member on the surface layer portion of the ceramic member. There has been proposed a roller in which an anchor effect in which a resin member wraps around the joint surface of a ceramic member is produced and the joint strength is improved (Patent Document 1).

  Also, as a method other than resin molding, a thermoplastic resin member is used and bonded to the contact surface between the ceramic member and the resin member by ultrasonic vibration, thereby joining the insulating plate made of the ceramic member and the thermoplastic resin. The thermal fuse which welded the plate of this by ultrasonic vibration was shown (patent document 2).

  As a technique using a porous member in welding by ultrasonic vibration, a decorative button in which a thermoplastic porous core material such as urethane foam and a thermoplastic adhesive sheet are sandwiched and superposed on a cloth fabric is ultrasonically welded. Has been proposed (Patent Document 3).

Furthermore, a multilayer substrate for an electronic circuit using a ceramic composite in which a resin is filled in an open pore of a porous ceramic having a three-dimensional network-like open pore has been proposed. The ceramic composite that constitutes this multilayer substrate for electronic circuits has a three-dimensional crystal structure and is filled with resin in its open pores. A technique for improving the image quality has been known (Patent Document 4).
JP 2002-309031 A JP 2002-237240 A JP-A-8-10009 Japanese Patent Publication No. 6-34435

  However, in the method using a resin mold as disclosed in Patent Document 1, there is a problem that the ceramic member is damaged by the molding pressure of the resin injected into the mold when the ceramic member is molded. Therefore, it is necessary to set the molding pressure lower than usual at the time of resin molding, and the dimensional accuracy of the resin molded product is often inferior.

  In addition, since the resin injected into the mold is generally heated to 200 to 250 ° C., the ceramic member is suddenly heated by coming into contact with the injected resin, and is damaged by heat shock. It was.

  When the clearance between the ceramic member to be inserted and the resin mold is large, the ceramic member moves inside the die, and thus there is a problem in that the positioning varies. Conversely, in order to reduce the clearance, it is necessary to process the ceramic member with high accuracy. Since the ceramic member is a difficult-to-process material, the cost has been increased in order to achieve high dimensional accuracy.

  Moreover, in the method of joining by the ultrasonic vibration welding to the contact surface of a ceramic member and a resin member using the thermoplastic resin member which is disclosed by patent document 2, the joint strength of a contact surface is sufficient. There were small issues.

  As disclosed in Patent Document 1, as a method for increasing the bonding strength on the contact surface, a plurality of chipped portions or recesses due to chipping are provided at locations where the ceramic member comes into contact with the resin member, or the average filler particle size of the resin member It has been proposed to provide a dense layer having pores of a diameter or larger on the surface layer portion of the outer peripheral surface of the ceramic member, aiming at an anchor effect in which the resin member wraps around the joint surface of the ceramic member. When the member is resin-molded, it is necessary to set the injection molding pressure low, and even if pores are provided only in the surface layer, it is difficult to sufficiently produce the anchor effect described above.

  Further, the welding by ultrasonic vibration disclosed in Patent Document 3 uses a soft porous member such as urethane foam, and does not relate to a ceramic member.

  And the ceramic composite which filled resin in the open pore of the porous ceramic which has the open pore of the three-dimensional network shape currently disclosed by patent document 4 is gas-impermeable while improving the machinability of a product. In order to maintain the performance, the open pores are filled with a resin, and since the filled resin is not intended for bonding with other parts, there is a problem that the bonding strength is not sufficient.

  In view of the above problems, the present invention includes a ceramic member partially having a porous region having a three-dimensional network structure on the surface and a resin member having a protrusion, and joining the porous region and the protrusion. It is a resin-ceramic bonded body having a bonding region, wherein the bonding region is formed by impregnating a part of the resin forming the protrusion into the porous region of the ceramic member. To do.

  In addition, the resin-ceramic bonded body is characterized in that the pores in the bonding region and the proportion of the resin impregnated in the pores are 15 to 40% by volume with respect to the bonding region.

  Further, the porous region of the ceramic member has a porosity of 5 to 30%.

  And it is the manufacturing method of the above-mentioned resin-ceramic bonding body, Comprising: The said ceramic member and the said resin member were joined by ultrasonically welding the said protrusion part with respect to the said porous area | region. .

  In the present invention, the bonding region between the porous region and the protruding portion is formed by impregnating the porous region with a part of the resin forming the protruding portion. -A ceramic joined body can be obtained.

  In addition, a resin-ceramic bonded body with higher bonding strength can be obtained by setting the proportion of the pores in the joining region and the resin impregnated in the pores to 15 to 40% by volume with respect to the joining region. it can.

  Further, since the porosity of the porous region of the ceramic member is 5 to 30%, the resin of the resin member can be impregnated into the pores of the porous region to increase the bonding strength, and the material strength of the porous region itself Can also be held high.

  In addition, by using only a portion requiring high strength, high hardness, etc. for the member as a ceramic member, the manufacturing cost is low and economically advantageous as compared with the case where the whole is formed from a ceramic member. .

  Furthermore, a resin-ceramic assembly excellent in positioning accuracy can be obtained by providing a protrusion on the resin member in advance and ultrasonically welding the protrusion to the porous region of the ceramic member.

  Hereinafter, the best mode for carrying out the present invention will be described.

  FIG. 1 is a perspective view showing a resin-ceramic assembly 1 of the present invention, and FIG. 2 is an exploded perspective view of FIG. 3 is a cross-sectional view schematically showing a cross section taken along line XX of FIG. 1, and FIG. 4 is an enlarged cross-sectional view of the bonding region.

  As shown in FIGS. 1 and 2, the present invention is a joined body 1 having a joining region 3 formed by joining a ceramic member 2 and a resin member 6, and a porous region 4 having a three-dimensional network structure in the joining region 3. The joined member 1 is obtained by impregnating a resin constituting the resin member 6 into a part of the porous member 4 of the ceramic member 2 having a part of the ceramic member 2.

  The state of the joining region 3 will be described with reference to a cross-sectional view shown in FIG. 4. The joining region 3 of the ceramic member 2 is partially provided with a porous region 4 having a three-dimensional network structure. The resin member 6 is joined by being impregnated with a part of the resin.

  Here, the porous region 4 having a three-dimensional network structure provided in the joining region 3 of the ceramic member 2 is provided with independent open pores 10 on the surface, as shown schematically in FIG. 10 has a part which is mutually connected inside.

  The state of the porous region 4 can be measured using a micromeritics (pore sizer-9310 type) whose measurement principle is the mercury intrusion method, and the average pore diameter and porosity can be obtained.

  3 and 4, the bonding region 3 is a resin member 6 as seen in the depth direction from the surface of the ceramic member 2 in the cross section of the surface where the porous region of the ceramic member 2 and the protrusion 9 are in contact with each other. The area | region which the resin of this impregnated is shown.

  The pores in the joining region 3 and the proportion of the resin impregnated in the pores (occupation proportion) are measured in advance by preparing a measurement sample from the porous region 4 of the ceramic member 2 and measuring the total pore volume of the porous material. (L1) is measured and calculated from the ratio of the total fine hole capacity (L2) measured by producing a measurement sample from the bonded region 3 of the bonded body 1 after impregnating the porous region 4 with the resin member 2. Ask.

  The ratio (occupation ratio) occupied by the pores in the bonding region 3 and the resin impregnated in the pores is determined by the formula (L1-L2) / L1.

  When a part of the resin member 6 is impregnated into the open pores 10 in the porous region 4, an anchor effect is generated in which the resin member wraps around the inside of the open pores 10 communicating with the three-dimensional network structure. Yes. The proportion of the pores in the joining region 3 and the resin impregnated in the pores (occupation proportion) is preferably 15 to 40% by volume with respect to the joining region 3. By setting the proportion of the resin in the bonding region 3 to 15% by volume or more, the anchor effect due to the wraparound of the resin member 6 impregnated as described above becomes sufficient, and the bonding strength of the bonded body 1 can be increased. The material strength of the region 3 itself will be increased. However, when the proportion of the resin in the joining region 3 exceeds 40% by volume or more, the three-dimensional network structure of the porous region 3 is destroyed by the impregnation load when the resin member 2 is impregnated into the porous region 3. The anchor effect due to the wraparound of the member 6 is reduced, and the joint strength of the joined body 1 cannot be increased.

  The porous state of the porous region 4 of the ceramic member 2 preferably has a porosity in the range of 5 to 30%. If the porosity is less than 5%, the resin member 6 does not impregnate the porous region 4, so that the bonding is insufficient. If the porosity exceeds 30%, the material strength of the porous region 4 itself decreases and impregnation occurs. It becomes difficult to hold the resin member 6 and the bonding strength is lowered.

  Moreover, it is preferable that the average pore diameter of the porous area | region 4 which is a three-dimensional network structure is 3-10 micrometers. As in the case of the porosity, if the average pore diameter of the three-dimensional network structure of the porous region 4 is less than 3 μm, the resin member 6 does not impregnate the porous region 4 and bonding is insufficient. If the average pore diameter exceeds 10 μm, the material strength of the porous region 4 itself decreases and it becomes difficult to hold the impregnated resin member 6, and the bonding strength decreases.

  Furthermore, by forming the porous region 4 having such a three-dimensional network structure only in the joining region of the joining surface, deformation of the resin member in the joining region 3 can be suppressed. That is, since there is a difference in thermal expansion coefficient between the ceramic member 2 and the resin member 6, the bonded body 1 is likely to be affected by thermal expansion due to a temperature difference when the entire bonding surface is bonded. Moreover, in order to suppress the manufacturing cost of the ceramic member 2, the specification should be such that the joint surface of the ceramic member 2 is not burned and ground, but there is a waviness in the joint surface when the ceramic member 2 is left open. When the entire surface is joined to the resin member 6, there is a disadvantage that the resin member is distorted.

  As such a ceramic member 2, it is preferable to use a highly rigid ceramic represented by alumina, zirconia, silicon carbide, silicon nitride, and aluminum nitride.

  In order to make the ceramic member 2 partially having a porous region having a three-dimensional network structure on the surface, the green density of the green body before firing is formed to be lower than a predetermined value in the ceramic member manufacturing process. And firing. In particular, it is possible to form only a part of the ceramic member 2 as a porous region 4 having a three-dimensional network structure by forming and firing the joining region 3 of the ceramic member 2 partially in a state of low raw density. Become. Specifically, by providing a recess in a part of the mold for molding the ceramic powder, and controlling the green density of the molded body before firing by making a difference in the compression ratio when molding the ceramic powder. Is possible.

  The resin member 6 is made of a thermoplastic resin such as ABS, polycarbonate, polypropylene, polyacetal, PET, or PPS. In order to increase the rigidity of the resin member, a resin reinforced with glass fiber may be used.

  As a method of obtaining the joined body 1 by impregnating the porous region 4 with the resin member 6, a method by ultrasonic welding is particularly preferable. And after providing the projection part 9 in the joining surface 7 of the resin member 6 previously, combining the porous area | region 4 of the said ceramic member 2 and this projection part 9, this projection part 9 is ultrasonically welded. A resin-ceramic assembly can be obtained by impregnating the porous region 4 with a resin.

  The protrusion 9 provided on the resin member 6 is for melting by ultrasonic vibration and impregnating the contacting ceramic member 2, and the cross section of the protrusion 9 is preferably triangular or trapezoidal, and the size is the width of the base By setting the height to 1 mm or less and the height of 0.2 mm to 0.5 mm, the melted protrusion 9 can uniformly spread and impregnate into the porous region 4 of the ceramic member 2.

  And in order to perform favorable ultrasonic welding, it is good to set the pressure to pressurize to 0.1-0.4 MPa, the frequency of ultrasonic vibration to 10-30 kHz, and the welding time to 0.1-1 second.

  In particular, since the ultrasonic transmission force of the ceramic member 2 is high, when the pressure to be applied is high, or when the welding time is long, the protrusion 9 is excessively dissolved by ultrasonic vibration, so that the bonding becomes incomplete.

  Examples of the present invention will be described below.

  Each material of the resin-ceramic bonded body shown in FIG. 1 was manufactured under the specification conditions shown in Table 1.

  The size of the joined body was an outer diameter of φ20 mm, a ceramic member thickness of 30 mm, a resin member thickness of 30 mm, an overall thickness of 60 mm, a circular shape formed on the joint surface of the protrusion of the resin member, and a central diameter of 17 mm. .

  Bonding is performed using an ultrasonic dressing machine, and a sample of the bonded body is manufactured under the conditions of ultrasonic pressure, setting the pressure to be applied to 0.2 MPa, the frequency of ultrasonic vibration to 15 kHz, and the welding time to 0.5 seconds. (Example No. 2 to No. 9).

  In addition, as a comparative example, a sample was manufactured in the same manner as in the example without forming a partial porous three-dimensional network structure on the ceramic member.

  The coaxiality and tensile fracture load of this joined body were measured.

  The coaxiality of the joined body was determined by measuring the degree of deflection of the resin member when the joined body was rotated with reference to the outer diameter of the ceramic member.

  The tensile fracture load was determined by measuring the load at which the bonded surface peels when the obtained bonded body is pulled in the direction opposite to the pressure surface during bonding.

The results are shown in Table 1.

  The joined body of the ceramic member and the resin member of the present invention has a tensile fracture load strength of 50 N or more as compared with the comparative example, and it has been found that the joined body has high joint strength.

It is a perspective view which shows the resin-ceramics assembly which concerns on this invention. It is a perspective view which shows the state before joining the resin-ceramics assembly which concerns on this invention. FIG. 2 is a cross-sectional view taken along line XX in the resin-ceramic bonded body of FIG. 1. It is sectional drawing which shows the joining area | region in the resin-ceramics assembly which concerns on this invention. It is a schematic diagram which shows the three-dimensional network structure of the joining area | region in the resin-ceramic joining body which concerns on this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Bonded body 2 ... Ceramic member 3 ... Bonding area | region 4 ... Porous area | region 5 ... Pressurizing surface 6 ... Resin member 7 ... Joining surface 8 ... Pressurizing surface 9 of resin member ... Protrusion part 10 ... Open-pore

Claims (4)

A resin-ceramic having a joining region formed by joining the porous region and the projecting portion, comprising a ceramic member partially having a porous region having a three-dimensional network structure on the surface and a resin member having a projecting portion. It is a joined body, The said joining area | region is formed by impregnating a part of resin which forms the said protrusion part in the porous area | region of the said ceramic member, The resin-ceramic joined body characterized by the above-mentioned. 2. The resin-ceramic bonded body according to claim 1, wherein a ratio of pores in the joining region and a resin impregnated in the pores is 15 to 40% by volume with respect to pores of the joining region. The resin-ceramic assembly according to claim 1 or 2, wherein the porous region of the ceramic member has a porosity of 5 to 30%. It is a manufacturing method of the resin-ceramics assembly in any one of Claims 1 thru | or 3, Comprising: The said ceramic member and the said resin member are bonded by ultrasonically welding the said protrusion part with respect to the said porous area | region. A method for producing a resin-ceramic bonded body, characterized by being bonded.

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