JP6484808B2 - Insert molded product - Google Patents

Description

  The present invention relates to an insert molded product.

  As shown in Patent Document 1, a bus bar device including a noise filter (hereinafter referred to as a bus bar device with a noise filter) is known. In this type of apparatus, a metal long bus bar is disposed so as to penetrate a ferrite core as a magnetic body. An insulating resin layer is interposed between the ferrite core and the bus bar so as to go around the bus bar. The resin layer is bonded to the ferrite core and the bus bar. The resin layer is fixed to a bus bar or the like by insert molding using a predetermined mold.

JP 2014-82738 A

  The resin layer is required to have not only adhesion to a bus bar and the like, but also water stopping properties to block water droplets moving along the bus bar. However, the conventional resin layer has a limit in adhesion to the bus bar, and it has been difficult to ensure sufficient water-stopping with the resin layer alone. Therefore, conventionally, sealing between the resin layer and the bus bar has been performed using a sealing material (for example, silicone rubber).

  An object of the present invention is to solve the above-described problems and achieve the following objects. That is, an object of the present invention is to provide an insert molded product that is excellent in adhesion between the insert member and the resin member and water-stopping property.

  As a result of intensive studies to achieve the above object, the inventors have made a metal-based core material made of a metal or an alloy, an insert member having a plating layer formed on the surface of the core material, A primer layer formed by applying a primer to the plating layer, and a resin member disposed so as to sandwich the primer layer between the insert member and fixed to the insert member via the primer layer, The plating layer is any one selected from the group consisting of a zinc trivalent chromate plating layer in which a trivalent chromate plating layer is laminated on a zinc plating layer, a nickel plating layer, and a tin plating layer, and the primer is an epoxy The resin member is made of an unsaturated polyester resin or a phenol resin. Insert molded article, adhesion, and found that superior water cut, thereby completing the present invention.

  In the insert molded article, the core material is preferably any one selected from the group consisting of tough pitch copper, brass, and carbon steel.

  In the insert molded article, the insert member may be made of a bus bar, and the resin member may be made of an insulating layer fixed to the bus bar via the primer layer.

  ADVANTAGE OF THE INVENTION According to this invention, the insert molded product excellent in the adhesiveness between an insert member and a resin member and water-stopping property can be provided.

Cross-sectional view schematically showing an example of an insert molded product Top view of insert member Disassembled perspective view of mold for insert molding Plan view of test sample (insert molded product)

(Insert molded product)
An embodiment of the present invention will be described with reference to FIG. FIG. 1 is a cross-sectional view schematically showing an example of an insert molded product 1. This insert molded product 1 constitutes a part of a bus bar device with a noise filter (not shown) applied to, for example, a DC / DC converter of a hybrid vehicle.

  The insert molded product 1 includes a longitudinal bus bar 10 as an insert member, a cylindrical ferrite core (magnetic body) 20 surrounding the bus bar 10 so that the bus bar 10 penetrates the inside, and the bus bar 10 and the ferrite core 20. A resin layer (resin member) 30 is provided so as to circulate around the bus bar 10 and insulate the bus bar 10 and the ferrite core 20 while fixing each other.

  The insert molded product 1 has a predetermined insulating property between a bus bar (insert member) 10 and a ferrite core 20 that have been previously subjected to primer treatment (primer treatment layer 40) by insert molding using a predetermined mold. The resin layer (resin member) 30 made of a thermosetting resin or the like having the above is formed. That is, in the insert molded product 1, the resin layer (the resin member 30 is fixed to the bus bar (insert member) 10 via the primer-treated portion (primer-treated layer 40). Since it cannot be fixed directly to the bus bar (insert member) 10, it is fixed via the primer treatment layer 40.

(Insert material)
The insert member (such as the bus bar 10) includes a metal-based core material made of a metal or an alloy, and a plating layer formed on the surface of the core material. There is no restriction | limiting in particular as a metal utilized for a core material, Although it selects suitably according to the objective, For example, copper, brass, etc. are mentioned. The alloy used for the core material is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include carbon steel which is an alloy of iron and carbon.

  The plating layer formed on the surface of the core material is any one selected from the group consisting of a zinc trivalent chromate plating layer in which a trivalent chromate plating layer is laminated on a zinc plating layer, a nickel plating layer, and a tin plating layer. It consists of. These plating layers are formed using a known plating method. The thickness of the plating layer is not particularly limited as long as the object of the present invention is not impaired, but is preferably about 10 μm, for example.

(Resin member)
As the resin member (resin layer 30 or the like), an unsaturated polyester resin or a phenol resin is used.

  Examples of unsaturated polyester resins include resins obtained by esterifying aliphatic unsaturated dicarboxylic acids and aliphatic diols (for example, unsaturated dicarboxylic acids such as maleic acid and fumaric acid, ethylene glycol and diethylene glycol). Resin obtained by esterification reaction with a diol such as

  Moreover, as unsaturated polyester resin, you may utilize in the form of BMC (Bulk Molding Compound) which is a thermosetting molding material which has unsaturated polyester resin as a main component, for example. Specific examples of the unsaturated polyester resin include those exemplified in the examples.

  The phenol resin may be either a novolak type (for example, a novolak type cured with hexamethylenetetramine) or a resol type (for example, a solid resol mainly composed of dimethylene ether bonds). Specific examples of the phenol resin include those exemplified in the examples.

(Primer)
Examples of the primer used for the primer treatment (primer treatment layer) include an epoxy-based primer and a nylon-based primer. Examples of the epoxy primer include a modified epoxy resin obtained by increasing the molecular weight and functionality of a bisphenol A type epoxy resin using a predetermined modifier. Specific examples of the epoxy primer include those exemplified in the examples.

  Examples of the nylon-based primer include a modified nylon resin obtained by modifying a thermoplastic nylon into a thermosetting type and having a three-dimensional network structure through a crosslinking reaction during heating and melting. Specific examples of the nylon primer include those exemplified in the examples.

  When the resin member is made of an unsaturated polyester resin, any of an epoxy primer and a nylon primer may be used as the primer. On the other hand, when the resin member is made of a phenol resin, an epoxy primer is used as the primer.

  When the resin member is made of an unsaturated polyester resin, the primer is preferably an epoxy primer from the viewpoint of heat resistance and the like.

  The primer is applied to the insert member by a known application method (coating, dipping, spraying, etc.). Moreover, a primer is provided to the range which overlaps with a resin member at least with respect to an insert member.

  It has been confirmed that even when a vinyl ester resin is used as a primer, the insert member and the resin member cannot be adhered to each other.

  The insert-molded article of the present invention is excellent in adhesion between the insert member and the resin member, and is excellent in water-stopping property.

  The insert molded product of the present invention is not limited to the above-described bus bar device with a noise filter, and can be used in various products.

  Hereinafter, the present invention will be described in more detail based on examples. In addition, this invention is not limited at all by these Examples.

[Test 1: When the resin member is an unsaturated polyester resin]
Test samples of Examples 1 to 18 and Comparative Examples 1 to 18 were produced according to the procedure shown below.

  An insert member (metal piece) 10 having a size (length: 60 mm, width: 12 mm, thickness: 2 mm) as shown in FIG. 2 and a configuration (plating layer, core material) shown in Table 1 is prepared. did.

  Next, on one surface of one end side of the insert member 10, 1 or 2 drops (total of about 0.03 g) of the primer shown in Table 1 is dropped with a dropper, and then spread with a spatula. One point shown in FIG. A coating film (primer-treated layer) made of a primer was formed in a range surrounded by a chain line (vertical: 30 mm, horizontal: 10 mm).

  In the comparative example, when the primer was not applied to the insert member 10, the procedure proceeded to the next procedure described later.

  FIG. 3 is an exploded perspective view of a mold M for insert molding. Here, the mold M will be briefly described. The mold M includes a lower mold M1, an upper side M2, and a core M3. The lower mold M1 is provided with a recess m11 in which the insert member 10 is set during molding. Further, convex portions (guide pins) m12 and m13 for positioning are provided upright on the upper surface of the lower mold M1.

  The core M3 is a portion that is held between the lower mold M1 and the upper mold M2 during mold clamping, and has a flat plate shape as a whole. A through-hole-shaped resin molding part m31 for molding a resin member is provided in the approximate center of the core M3. The resin molding part m31 has a longitudinal shape, and one end thereof is set so as to overlap the end part of the insert member 10 set on the lower mold M1 at the time of clamping. The other end of the resin molding part m31 does not overlap with the insert member 10 but does not overlap with the flat upper surface of the lower mold M1 during mold clamping. In addition, the space for accommodating the raw material for resin members is formed between the resin molding part m31 and the lower mold | type M1 in which the insert member 10 was set.

  In addition, the part which the edge part of the insert member 10 and the resin molding part m31 overlap corresponds to the range enclosed by the dashed-dotted line shown by FIG. The core M3 is provided with through-hole positioning portions m32 and m33 through which the convex portions (guide pins) m12 and m13 of the lower die M1 are inserted when the mold is clamped.

  The lower surface of the upper mold M2 is flat, and functions to close the through-hole-shaped resin container m31 from above during mold clamping. The upper mold M2 is provided with through-hole positioning parts m22 and m23 that are fitted to the convex parts (guide pins) m12 and m13 of the lower mold M1 when the mold is clamped.

  The insert member 10 coated with the primer was set on the mold M (lower mold M1) as described above so that the primer coating film faced upward (upper mold M2 side). In the comparative example, when the primer was not applied to the insert member 10, it was set in the mold M (lower mold M1) as it was.

  Subsequently, the core M2 was overlaid on the lower mold M1, and the resin molding part m31 was filled with a raw material for the resin member (unsaturated polyester resin) (pasted unsaturated polyester resin). Thereafter, a release film (trade name “Purex A50”, manufactured by Teijin DuPont Films Ltd.) was placed on the core M3 so as to cover the resin molding part m31, and the upper mold M2 was stacked on the core M3. .

  Subsequently, the mold M is placed in a small heating manual press (product number “IMC-1800 type”, Imoto Seisakusho Co., Ltd.) and clamped. Molding temperature: 150 ° C., press pressure: 20 MPa, molding time: 3 minutes Under such conditions, press molding (insert molding) was performed.

  Thereafter, the mold M was opened, and a test sample (insert molded product) in which the resin member (unsaturated polyester resin) 30 was fixed to the insert member 10 from the mold M was obtained. The resin member 30 has a length of 60 mm, a width of 10 mm, and a thickness of 2 mm. FIG. 4 is a plan view of a test sample (insert molded product).

The details of each component shown in Table 1 are as follows.
(Resin member)
Unsaturated polyester resin: Trade name “CE2925 970R” (manufactured by Panasonic Corporation)
(Plating layer)
Zn (trivalent Cr): zinc trivalent chromate plating layer in which a trivalent chromate plating layer is laminated on a zinc plating layer Ni: nickel plating layer Sn: tin plating layer (core material)
Tough pitch copper: C1100 Tough pitch copper Brass: C2600 brass Carbon steel: S45C carbon steel (primer)
Epoxy: Trade name “Aron Mighty AS-60” (manufactured by Toagosei Co., Ltd., modified epoxy resin, methanol / toluene solvent, solid content 22 wt%)
Nylon type: Trade name “Aron Mighty FS-175SV10” (manufactured by Toagosei Co., Ltd., modified nylon, modified ethanol solvent, solid content 10 wt%)

(Tensile test)
About the obtained test sample of Examples 1-18, the tension test was done. For the tensile test, a desktop precision universal testing machine (trade name “AGS-X”, manufactured by Shimadzu Corporation) is used, and both ends of the test piece (end on the insert member side and end on the resin member side) Was carried out by pulling away from each other along the vertical direction. The results are shown in Table 1. In Table 1, the symbol (* 1) is given when the resin member is damaged before the insert member (metal piece) and the resin member are peeled off. The tensile strength (MPa) at the time of failure was shown.

  In each comparative example, the insert member and the resin member were not fixed, and could not be taken out from the mold M as a molded product. Therefore, for each comparative example, a tensile test could not be performed, and in Table 1, the evaluation result was described as “not measurable”.

(Evaluation of water stoppage (adhesion))
When the result of the tensile test exceeded 50 MPa, it was determined that the adhesion between the insert member and the resin member was ensured and water-stopping was provided (symbol “◯”). On the other hand, when the result of the tensile test was 50 MPa or less, it was determined that the adhesion between the insert member and the resin member was not ensured and no water-stopping property was provided (symbol “x”). The results are shown in Table 1.

  As shown in Table 1, it was confirmed that the test samples (insert molded products) of Examples 1 to 18 were provided with water-stopping properties (adhesiveness).

[Test 2: When the resin member is a phenol resin]
The resin member was replaced with a phenolic resin (trade name “PM-9640”, manufactured by Sumitomo Bakelite Co., Ltd.), the molding temperature was changed to 180 ° C., and the press pressure was changed to 60 MPa. Test samples (insert molded products) of Examples 19 to 32 and Comparative Examples 19 to 36 were prepared using the insert member and the primer shown in Table 2.

  The components shown in Table 2 are the same as those shown in Table 1 of Test 1 above. About the obtained test sample of Examples 19-32, the tensile test and the water-stop (adhesiveness) evaluation were performed like the said test 1. FIG. The results are shown in Table 2.

  In each comparative example, the insert member and the resin member were not fixed, and could not be taken out from the mold M as a molded product. Therefore, for each comparative example, a tensile test could not be performed, and in Table 2, the evaluation result was described as “not measurable”.

  As shown in Table 2, it was confirmed that the test samples (insert molded products) of Examples 19 to 32 were provided with water-stopping properties (adhesiveness). On the other hand, about the test sample of Comparative Examples 19-36, it was confirmed that the resin member is not closely_contact | adhered to an insert member and is not provided with water stop (adhesiveness).

  DESCRIPTION OF SYMBOLS 1 ... Insert molded product, 10 ... Insert member (bus bar), 20 ... Ferrite core, 30 ... Resin member (resin layer, insulating layer), 40 ... Primer processing layer

Claims (3)

An insert member having a metal-based core material made of a metal or an alloy, and a plating layer formed on the surface of the core material;
A primer layer formed by adding a primer to the plating layer;
A resin member disposed so as to sandwich the primer layer between the insert member and fixed to the insert member via the primer layer;
The plating layer is any one selected from the group consisting of a zinc trivalent chromate plating layer obtained by laminating a trivalent chromate plating layer on a zinc plating layer, a nickel plating layer, and a tin plating layer,
The primer comprises an epoxy primer or a nylon primer,
An insert-molded article, wherein the resin member is made of an unsaturated polyester resin or a phenol resin.   The insert molded article according to claim 1, wherein the core material is any one selected from the group consisting of tough pitch copper, brass, and carbon steel. The insert member comprises a bus bar,
The insert-molded product according to claim 1 or 2, wherein the resin member is made of an insulating layer fixed to the bus bar via the primer layer.

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