JP6870189B2 - Manufacturing method of insert molded product and insert molded product - Google Patents

Description

The present invention relates to a method for producing an insert molded product and an insert molded product.

Insert molding is widely known as one of the molding methods for a composite of a resin and other members. Insert molding is performed by injecting molten resin into a mold in which an insert member is arranged. By insert molding, a composite in which various combinations of different materials such as a composite of a resin and a metal and a composite of different resins are joined can be molded into a desired shape.

On the other hand, fluororesin is excellent in slidability, releasability, heat resistance, chemical resistance, weather resistance and the like. Therefore, fluororesins are used as coating materials for various products. Further, there is also known a technique for improving the wear resistance and adhesion of the fluororesin by irradiating the molten fluororesin with ionizing radiation to cause a cross-linking reaction (Japanese Patent Laid-Open No. 2013-027875, Japanese Patent Application Laid-Open No. 2011). -074938A and 3702801A).

Japanese Unexamined Patent Publication No. 2013-027875 Japanese Unexamined Patent Publication No. 2011-074938 Japanese Patent No. 3702801

It is expected that the above-mentioned insert molded product will also be improved in performance by using the crosslinked fluororesin. However, in order to crosslink the fluororesin, it is necessary to irradiate ionizing radiation at a temperature equal to or higher than the melting point of the fluororesin, for example, about 320 to 400 ° C. Therefore, when the insert molded product is coated with an uncrosslinked fluororesin and irradiated with ionizing radiation at a temperature equal to or higher than the melting point of the fluororesin, the resin of the insert molded product melts or softens. Therefore, the insert molded body is deformed and the accuracy of the shape and the like is lowered. On the other hand, it is also conceivable to perform insert molding using the crosslinked fluororesin as the insert member. However, since the fluororesin has low adhesion to other resins, it is not possible to obtain an insert molded product having high adhesion.

The present invention has been made based on the above circumstances, and includes a method for producing an insert molded product containing a crosslinked fluororesin and having excellent shape accuracy and adhesion, and a crosslinked fluororesin. An object of the present invention is to provide an insert molded product having excellent shape accuracy and adhesion.

In one aspect of the present invention made to solve the above problems, a first member containing a fluororesin as a main component and a second member containing a component other than the fluororesin as a main component are joined by irradiation with ionizing radiation. This is a method for manufacturing an insert molded product, comprising a step of obtaining the insert member and a step of molding the resin member on the surface region including the exposed portion of the second member of the insert member by insert molding.

In another aspect of the present invention, a first member containing a fluororesin as a main component and a second member containing a component other than the fluororesin as a main component are bonded, and the first member and the second member are chemically bonded. It is an insert molded body including an insert member that is bonded or mutually diffused, and a resin member formed on a surface region including a portion of the insert member where the second member is exposed.

The present invention provides a method for producing an insert molded product containing a crosslinked fluororesin and having excellent shape accuracy and adhesion, and an insert molded product containing a crosslinked fluororesin and having excellent shape accuracy and adhesion. can do.

FIG. 1 is an explanatory diagram of step A in the method for manufacturing an insert molded product according to the first embodiment of the present invention. FIG. 2 is an explanatory diagram of step B in the method for manufacturing an insert molded product according to the first embodiment of the present invention. FIG. 3 is an explanatory diagram of step A in the method for manufacturing an insert molded product according to a second embodiment of the present invention. FIG. 4 is an explanatory view of step B in the method for manufacturing an insert molded product according to the second embodiment of the present invention. FIG. 5 is an explanatory diagram of step A in the method for manufacturing an insert molded product according to a third embodiment of the present invention. FIG. 6 is an explanatory diagram of step B in the method for manufacturing an insert molded product according to a third embodiment of the present invention. FIG. 7 is a plan view showing an insert member in a method for manufacturing an insert molded product according to another embodiment of the present invention. FIG. 8 is a plan view showing an insert member in a method for manufacturing an insert molded product according to another embodiment of the present invention.

[Explanation of Embodiments of the Present Invention]
In the method for producing an insert molded article according to one aspect of the present invention, a first member containing a fluororesin as a main component and a second member containing a component other than the fluororesin as a main component are joined by irradiation with ionizing radiation. This is a method for manufacturing an insert molded product, which comprises a step of obtaining an insert member and a step of molding a resin member on a surface region including a portion of the insert member where the second member is exposed. The "main component" refers to a component having the highest content on a mass basis, and is preferably a component having a content of more than 50% by mass.

In the manufacturing method, the resin member is molded on the surface region including the exposed portion of the second member whose main component is a component other than the fluororesin in the insert member by insert molding. Therefore, according to the manufacturing method, it is possible to obtain an insert molded product having excellent adhesion between the insert member containing the fluororesin and the resin member. Further, in the manufacturing method, ionizing radiation for cross-linking the first member containing a fluororesin as a main component is irradiated before the insert molding. Therefore, since the resin member (insert molding resin) molded by insert molding is not placed at a high temperature, the resin member does not melt or soften again, and an insert molded body having excellent shape accuracy can be obtained. Can be done. Further, by using the second member having an expansion coefficient close to that of the resin member, wrinkles, floating, peeling and the like due to the difference in expansion coefficient between the fluororesin and the resin member can be suppressed. Examples of the combination of the resin member having a similar expansion coefficient and the second member include a combination of a liquid crystal polymer (LCP) and a copper alloy, aluminum, or the like. Further, in the manufacturing method, unevenness such as embossing is applied to the exposed surface of the first member containing the crosslinked fluororesin by processing immediately before insert molding or injection compression during insert molding. It is also possible to improve shape accuracy and productivity. In addition, in the insert molded body in which the surface of the first member is subjected to such uneven processing, there is an advantage that friction is reduced.

It is preferable that the surface region of the insert member has an uneven shape. Thereby, the adhesion between the insert member and the resin member in the obtained insert molded body can be further improved. The "concavo-convex shape" in this surface region may be formed only by the second member, or may be formed by the first member and the second member.

It is preferable that the second member is a sheet, and the ionizing radiation is irradiated in a state where the first member is laminated on one surface of the sheet as the second member. By doing so, it is possible to effectively obtain an insert molded product having a crosslinked fluororesin layer on the surface.

It is preferable that the surface of the sheet in contact with the resin member is roughened. Thereby, the adhesion between the insert member and the resin member in the obtained insert molded body can be further improved.

It is preferable to irradiate the ionizing radiation with the second member being a woven fabric or a non-woven fabric and the first member impregnating a part of the woven fabric or the non-woven fabric as the second member. By doing so, the woven fabric or the non-woven fabric as the second member forms a concavo-convex shape in the surface region of the insert member, so that an insert molded body having better adhesion of the resin member can be obtained.

It is also preferable to irradiate the ionizing radiation with one or more second members arranged on a part of the surface of the first member. Even in this case, the adhesion of the resin member to be insert-molded can be further enhanced by the structure of the second member, the structure of the combination of the first member and the second member, and the like.

It is preferable that the main component of the second member is a resin other than metal or fluororesin. By using a resin other than metal or fluororesin, it is possible to further improve the adhesion of the resin member to be insert-molded. Moreover, the thermal conductivity of the metal is higher than the thermal conductivity of the fluororesin. Therefore, when a metal is used, the local temperature rise when the obtained insert molded product is subjected to high-temperature treatment such as a laser or slid is alleviated by heat dissipation, which has the effect of improving durability. .. Further, by using a metal, the surface hardness of the obtained insert molded product can be improved.

It is preferable that the insert member is a lead frame. The manufacturing method can be suitably used for insert molding of a lead frame having a layer containing a crosslinked fluororesin.

In the insert molded product according to one aspect of the present invention, a first member containing a fluororesin as a main component and a second member containing a component other than the fluororesin as a main component are joined, and the first member and the second member are joined. It is an insert molded body including an insert member in which and is chemically bonded or mutually diffused, and a resin member formed on a surface region including an exposed portion of the second member in the insert member.

The insert molded product contains a crosslinked fluororesin and is excellent in shape accuracy and adhesion. The "chemical bond" refers to a covalent bond, an ionic bond, and a hydrogen bond. Further, "mutual diffusion" means that a part of the components of the first member is diffused to the second member and a part of the components of the second member is diffused to the first member. When a mutual diffusion layer in which the components of the first member and the components of the second member coexist can be confirmed in the boundary region between the first member and the second member, the first member and the second member are mutually diffused. Can be considered to be.

[Details of Embodiments of the present invention]
<First Embodiment>
(Manufacturing method of insert molded product)
The method for manufacturing an insert molded product according to the first embodiment of the present invention includes a step A for obtaining an insert member and a step B for molding a resin member on a predetermined surface region of the insert member by insert molding in this order.

(Step A)
Step A is a step of obtaining an insert member in which a first member containing a fluororesin as a main component and a second member containing a component other than the fluororesin as a main component are joined by irradiation with ionizing radiation. This insert member is a member of various electronic parts such as a lead frame and other parts.

Specifically, as shown in FIG. 1, first, the first member 11 is laminated on one surface 12a of the sheet 12, which is the second member.

The main component of the sheet 12 is not particularly limited as long as it is a component other than the fluororesin. However, it is preferable that the sheet 12 is hard to soften and deform when the fluororesin is melted by irradiation with ionizing radiation, so that the main component of the sheet 12 preferably has sufficient heat resistance. Examples of the main component of the sheet 12 which is the second member include metals, other inorganic materials, resins other than fluororesin, and the like, and it is preferable that the sheet 12 is a metal or a resin other than fluororesin.

Examples of the metal include aluminum, copper, iron, titanium, nickel, alloys thereof and the like. Examples of the other inorganic materials include ceramics, alumina, and glass. As the resin other than the fluororesin, an engineering plastic having a melting point of 300 ° C. or higher, a thermosetting resin, or a radiation crosslinked resin can be used because it does not melt at the crosslinking temperature of the fluororesin. Examples of such resins include polyetheretherketone, polyimide, polyamideimide, aramid, polybenzoimidazole, LCP, urea resin, phenol resin, melamine resin, silicon resin, epoxy resin, electron beam crosslinked polyamide and the like. it can.

When the insert member 13 is a lead frame, a metal such as aluminum, copper, or an alloy thereof can be preferably used as the main component of the sheet 12. The lower limit of the content of the metal or other main component in the sheet 12 which is the second member is preferably 90% by mass, more preferably 99% by mass. The content of the metal or other main component in the sheet 12 may be 100% by mass.

The first member 11 is laminated on one surface 12a of the sheet 12. On the other hand, the other surface 12b of the sheet 12 is roughened. That is, the surface 12b has an uneven shape. The other surface 12b is a surface region including an exposed portion of the sheet 12, which is a second member of the insert member 13 described later, and a resin member is formed on this surface region. That is, this surface 12b is a surface that comes into contact with the resin member 14 in the subsequent step B.

The roughening treatment can be performed by chemical etching, electrochemical etching, laser treatment, or the like. Examples of the chemical etching include known methods such as alkali etching and acid etching. Electrochemical etching is performed, for example, by applying alternating current, pulse current, or half-wave rectification to the sheet 12 while the sheet 12 is immersed in an aqueous solution containing chloride ions. As the laser treatment, a method of providing fine irregularities on the surface with a laser or a method of obtaining a surface having a complicated shape by a continuous wave laser can be used (Patent Nos. 5701414 and 5774246). The roughening treatment can also be performed by other physical treatments such as sandblasting, grid blasting, and shot blasting.

As the lower limit of the surface roughness of the other surface 12b of the sheet 12, for example, the arithmetic average roughness Ra is preferably 0.001 μm, more preferably 0.1 μm, further preferably 1 μm, further preferably 3 μm, and 5 μm. You may. By setting the arithmetic mean roughness Ra to be equal to or higher than the above lower limit, the resin member 14 can be more firmly adhered to the resin member 14 during insert molding. The upper limit of the arithmetic mean roughness Ra of the surface 12b is, for example, 1 mm and may be 300 μm. Here, the arithmetic mean roughness Ra is a value measured according to JIS B 0601: 2001.

In the sheet 12 of FIG. 1, the entire surface of the other surface 12b is roughened, but only the portion where the resin member 14 is laminated by insert molding may be roughened. .. Further, the surface 12a on the side of the sheet 12 on which the first member 11 is laminated may also be roughened. When the surface 12a is roughened, the adhesion between the sheet 12 which is the second member and the first member 11 whose main component is fluororesin, that is, the peel strength can be improved. The method of roughening treatment on the surface 12a and the preferable surface roughness can be the same as those on the surface 12b.

The average thickness of the sheet 12 is not particularly limited, and is appropriately set according to the intended use and the like. The lower limit of the average thickness of the sheet 12 may be, for example, 1 μm or 10 μm. The upper limit of the average thickness may be, for example, 5 mm or 1 mm. By setting the average thickness of the sheet 12 within the above range, it can be suitably used for, for example, manufacturing a lead frame.

The planar shape of the sheet 12 may be a square shape or the like, but it may be processed into a predetermined shape by punching or the like. In this case, the first member 11 may be laminated on the sheet 12 processed into a predetermined shape, or the first member 11 may be laminated on the sheet 12 and processed into a predetermined shape after being irradiated with ionizing radiation.

The first member 11 contains a fluororesin as a main component. The lower limit of the content of the fluororesin in the first member 11 is preferably 80% by mass, more preferably 95% by mass. The content of the fluororesin in the first member 11 may be 100% by mass.

In the above-mentioned fluorine resin, at least one of the hydrogen atoms bonded to the carbon atom in the main chain constituting the structural unit of the polymer chain is a fluorine atom or an organic group having a fluorine atom (hereinafter, also referred to as “fluorine atom-containing group”). Refers to those replaced with. The fluorine atom-containing group is one in which at least one of the hydrogen atoms in the linear, branched or cyclic organic group is substituted with a fluorine atom, and for example, a fluoroalkyl group, a fluoroalkoxy group, a fluoropolyether group and the like are used. Can be mentioned.

The "fluoroalkyl group" means an alkyl group in which at least one hydrogen atom is substituted with a fluorine atom, and includes a "perfluoroalkyl group". Specifically, a "fluoroalkyl group" is a group in which all hydrogen atoms of an alkyl group are substituted with fluorine atoms, and all hydrogen atoms other than one hydrogen atom at the end of the alkyl group are substituted with fluorine atoms. Includes atoms and the like.

The "fluoroalkoxy group" means an alkoxy group in which at least one hydrogen atom is substituted with a fluorine atom, and includes a "perfluoroalkoxy group". Specifically, the "fluoroalkoxy group" is a group in which all hydrogen atoms of the alkoxy group are substituted with fluorine atoms, and all hydrogen atoms other than one hydrogen atom at the end of the alkoxy group are substituted with fluorine atoms. Includes atoms and the like.

A "fluoropolyether group" is a monovalent group having a plurality of alkylene oxide chains as a repeating unit and having an alkyl group or a hydrogen atom at the terminal, and the alkylene oxide chain and / or the alkyl group at the terminal or It means a monovalent group having a group in which at least one hydrogen atom in a hydrogen atom is substituted with a fluorine atom. The "fluoropolyether group" includes a "perfluoropolyether group" having a plurality of perfluoroalkylene oxide chains as a repeating unit.

Examples of the fluororesin include tetrafluoroethylene / hexaolopropylene copolymer (FEP), fluorinated ethylene-hexafluoropropylene copolymer (FEP), and tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer (PFA). , Polytetrafluoroethylene (PTFE) and tetrafluoroethylene-perfluorodioxol copolymer (TFE / PDD) are preferred. These can be used alone or in combination of two or more.

The first member 11 may contain an arbitrary component other than the fluororesin. Examples of this optional component include engineering plastics, flame retardants, flame retardants, pigments, antioxidants, antireflection agents, concealing agents, lubricants, processing stabilizers, plasticizers, foaming agents, reinforcing materials, hollow particles, and ceramics. Examples include fillers, inorganic fillers, and cloths.

The average thickness of the first member 11 is not particularly limited, and is appropriately set according to the application and the like. For example, the lower limit of the average thickness of the first member 11 may be, for example, 1 μm or 10 μm. The upper limit of the average thickness may be, for example, 5 mm or 1 mm. By setting the average thickness of the first member 11 in the above range, the obtained insert molded product can exhibit sufficient properties based on the crosslinked fluororesin such as wear resistance and slidability.

The method of laminating the first member 11 on the sheet 12 is not particularly limited. For example, a paint obtained by dispersing or dissolving a first member containing a fluororesin as a main component in a solvent is applied to one surface 12a of the sheet 12, and the film-like first member 11 is laminated by heating and drying. be able to. The coating may be powder coating. Further, the sheet 12 and the sheet-shaped first member 11 may be bonded together.

As shown in FIG. 1, the laminate in which the first member 11 is laminated on one surface 12a of the sheet 12 is heated to melt the fluororesin of the first member 11. In such a state, that is, in a state where the first member 11 is in contact with the surface 12a of the sheet 12 which is the second member and the fluororesin which is the main component of the first member 11 is melted, the first member 11 is charged. Irradiate with demarcation radiation. Specifically, the sheet 12 in which the first member 11 is laminated is placed in an oxygen-free atmosphere, for example, an atmosphere in which the oxygen concentration is 1000 ppm or less, and the surface of the first member 11 is irradiated with ionizing radiation while keeping the fluororesin in a molten state. To do. As a result, the fluororesin is crosslinked and chemically bonded or mutually diffused with the fluororesin and the components in the sheet 12, for example, a metal or a resin other than the fluororesin.

As the oxygen-free atmosphere, the oxygen concentration is preferably 100 ppm or less, and more preferably 10 ppm or less. If the oxygen concentration is high, the main chain of the fluororesin may be cut by irradiation with ionizing radiation. The temperature at which the fluororesin is melted is preferably 0 ° C. or higher and lower than 30 ° C. higher than the melting point of the fluororesin. When the fluororesin is heated to a temperature higher than the melting point by 30 ° C. or more, the thermal decomposition of the fluororesin may be promoted and the material properties may be deteriorated. The heating temperature can be, for example, 300 ° C. or higher and 400 ° C. or lower.

As the ionizing radiation, for example, γ-rays, electron beams, X-rays, neutron rays, high-energy ion rays and the like can be used. The irradiation dose of ionizing radiation is preferably 1 kGy or more and 1000 kGy or less, and more preferably 50 kGy or more and 500 kGy or less. If the irradiation dose is less than the above lower limit, the cross-linking reaction of the fluororesin may not proceed sufficiently. On the contrary, when the above upper limit is exceeded, the fluororesin may be easily decomposed.

By irradiating such ionizing radiation, the fluororesin in the first member 11 is crosslinked, and the insert member 13 in which the first member 11 and the sheet 12 which is the second member are in close contact with each other is obtained by chemical bonding. Can be done. The insert member 13 is in a state where the roughened surface 12b is exposed as a part of the sheet 12 which is the second member.

(Step B)
Step B is a step of molding the resin member 14 on the surface region including the exposed portion of the sheet 12, which is the second member of the insert member 13, by insert molding.

Specifically, as shown in FIG. 2, first, the insert member 13 is arranged in the mold 15. At this time, the resin member 14 is arranged so as to be laminated on the roughened surface 12b of the sheet 12 of the insert member 13. Although the flat plate-shaped insert member 13 is arranged in FIG. 2, the insert member 13 may be formed into a predetermined shape and arranged in the mold 15.

Next, by injecting the molten resin into the mold 15, the resin member 14 is formed on the surface region including the exposed portion of the second member of the insert member 13, that is, on the surface 12b of the sheet 12. The surface 12b on which the resin member 14 is formed is roughened as described above and has an uneven shape.

The resin member 14 contains a resin as a main component. As the resin of the resin member 14, a known resin used for insert molding can be used. Specific examples of this resin include polyolefins, polycarbonates, polyurethanes, polyesters, polystyrenes, polyvinyl chlorides, polyamides, LCPs and the like. When the insert member 13 is a lead frame or the like, LCP is preferably used as the resin member 14. The resin member 14 may contain an arbitrary component other than the resin. Examples of the optional component include those described above as the optional component of the first member 11.

By going through this step B, an insert molded body in which the resin member 14 and the insert member 13 are combined can be obtained.

(Insert molded product)
The insert molded body according to the embodiment of the present invention includes an insert member 13 and a resin member 14. The insert member 13 is a composite in which a first member 11 containing a fluororesin as a main component and a sheet 12 which is a second member containing a component other than the fluororesin as a main component are joined. The sheet 12 has a surface 12b that has been roughened and has an uneven shape. The first member 11 and the second member, the sheet 12, are chemically bonded or mutually diffused at the interface. Specifically, usually, the carbon atom of the main chain of the fluororesin, which is the main component of the first member 11, and the metal atom, which is the main component of the sheet 12, are covalently bonded or ionic bonded. An interdiffusion layer may be formed in the boundary region between the first member 11 and the sheet 12 which is the second member. Further, the fluororesin in the first member 11 is crosslinked. Specifically, the carbon atoms in the main chain of the fluororesin are covalently bonded to each other. The resin member 14 is formed on the surface 12b, which is a surface region including an exposed portion of the sheet 12, which is the second member of the insert member 13. The insert molded product can be obtained by the method described above as a method for producing the insert molded product.

(advantage)
In the manufacturing method according to the first embodiment, the resin member 14 is molded on the surface 12b of the sheet 12 which is the second member of the insert member 13 whose main component is a component other than the fluororesin by the insert molding. That is, the resin member 14 is molded on the surface region including the exposed portion of the insert member 13 containing the fluororesin, which is mainly composed of a component other than the fluororesin. Therefore, according to the manufacturing method, it is possible to obtain an insert molded product having excellent adhesion between the insert member 13 containing the fluororesin and the resin member 14. In particular, in the first embodiment, the surface 12b, which is the surface region of the insert member 13 on which the resin member 14 is formed, has a concavo-convex shape due to the roughening treatment. Thereby, the adhesion between the insert member 13 and the resin member 14 in the obtained insert molded product can be further improved.

Further, in the manufacturing method, ionizing radiation for cross-linking and adhering the first member 11 containing a fluororesin as a main component is performed before insert molding. Therefore, since the resin member 14 formed by insert molding is not placed at a high temperature, the resin member 14 does not melt or soften again, and an insert molded body having excellent shape accuracy can be obtained.

Further, the insert molded product contains a crosslinked fluororesin, and has excellent shape accuracy and adhesion. Therefore, the insert molded body is excellent in slidability, heat resistance, wear resistance, etc., and various electronic parts such as OA equipment, home appliances, automobiles, other transportation equipment, precision equipment, digital cameras, industrial machines, etc. It can be suitably used as a part or the like. For example, as a component of OA equipment, it can be used as a roller heater in a toner fuser, specifically, a ceramic heater or the like. By adopting a structure in which the heater is coated with a crosslinked fluororesin, it is possible to exhibit excellent slidability, wear resistance, etc. while having heat resistance. Further, when the surface of the first member (crosslinked fluororesin layer) is provided with an uneven structure, the insert molded body is suitable for reducing friction and supplying and holding grease and oil. Further, the insert molded body can be suitably used for a lead frame in which a resin member is injection-molded as an example of an electronic component. As described above, even in the production of a lead frame that requires high shape accuracy, the insert molded product containing the crosslinked fluororesin can be produced with sufficient accuracy according to the production method.

<Second Embodiment>
In the method for producing an insert molded product according to the second embodiment of the present invention, a woven fabric or a non-woven fabric is used as the second member containing a component other than the fluororesin as a main component. Specifically, as shown in FIG. 3, first, a part or all of the first member 21 containing a fluororesin as a main component is impregnated into a part of the second member 22 which is a woven fabric or a non-woven fabric. The impregnation of the first member 21 can be performed by, for example, placing the sheet-shaped first member 21 and the second member 22 on top of each other and heating the first member 21 to melt the first member 21. Further, the second member 22 which is a woven fabric or a non-woven fabric is impregnated with the first member 21 by applying a paint in which the first member containing a fluororesin as a main component is dispersed or dissolved in a solvent and drying the second member 22. be able to.

The second member 22 is a woven fabric or a non-woven fabric. That is, the second member 22 is made of fibers. The main component of the second member 22 can be the same as that of the sheet 12 in the first embodiment described above. That is, metals, other inorganic materials, resins other than fluororesins and the like can be mentioned, and resins other than metals and fluororesins are preferable.

The second member 22 is preferably a non-woven fabric. The method for producing the non-woven fabric is not particularly limited, and a known method for producing the non-woven fabric can be used. Specifically, for example, a fleece manufactured by a dry method, a wet method, a spunbond method, a melt blow method, etc. is subjected to a spunlace method, a thermal bond method, a needle punch method, a chemical bond method, a stitch bond method, a needle punch method, etc. Examples thereof include a method of bonding by an air-through method, a point bond method, or a method of forming a web by ejecting an adhesive fiber body at high speed by melt blowing.

In FIG. 3, the outer shapes of the first member 21 and the second member 22 are shown as a plate shape, but the shapes thereof are not limited to the plate shape.

As shown in FIG. 3, in step A, ionizing radiation is applied to the first member 21 in a state where the first member 21 is impregnated in a part of the second member 22 and the fluororesin of the first member 21 is melted. Irradiate. The method of irradiating the ionizing radiation can be the same as that of the first embodiment described above. Further, when the impregnation of the first member 21 is performed by heating and melting the first member 21, the impregnation of the first member 21 and the irradiation of ionizing radiation can be continuously performed while maintaining the heated state.

By irradiating this ionizing radiation, an insert member 23 in which the first member 21 and the second member 22 are joined can be obtained. As shown in FIG. 3, in the obtained insert member 23, a part of the second member 22 which is a woven fabric or a non-woven fabric is exposed. Further, since this exposed portion is a woven fabric or a non-woven fabric, the surface has an uneven shape. That is, the insert member 23 has a surface region 23x having an uneven shape including a portion where the second member 22 is exposed.

Next, as step B, the resin member 24 is molded on the surface region 23x of the obtained insert member 23. Specifically, as shown in FIG. 4, the insert member 23 is arranged in the mold 25. At this time, the resin member 24 is arranged so as to be laminated on the surface where a part of the second member 22 is exposed, that is, on the surface region 23x. The specific molding method of the resin member 24, that is, the injection method of the molten resin can be the same as that of the first embodiment described above.

From the viewpoint of adhesion, it may be preferable that the main component of the second member 22 is a resin. In this case, the resin that is the main component of the second member 22 and the resin member 24 are the same type of resin. Is more preferable. For example, it is preferable that the main components of the second member 22 and the resin member 24 are both LCP. In such a case, at the time of injection molding of the resin member 24, at least a part of the second member 22 is melted and the second member 22 and the resin member 24 are integrated, so that the adhesion is further improved.

By going through this step B, it is possible to obtain an insert molded body in which the resin member 24 in which the injected molten resin is solidified and the insert member 23 are composited.

(advantage)
In the manufacturing method according to the second embodiment, the woven fabric or the non-woven fabric as the second member 22 forms a concavo-convex shape in the surface region 23x of the insert member 23, and therefore, due to the adhesion between the insert member 23 and the resin member 24. An excellent insert molded product can be obtained. Further, as described above, by using a resin as the main component of the second member 22, the adhesion can be further improved.

<Third Embodiment>
As shown in FIG. 5, in the method for manufacturing an insert molded product according to the third embodiment of the present invention, as a step (step A) of obtaining an insert member, first, the surface of the first member 31 containing a fluororesin as a main component is used. One or more second members 32 are arranged in a part.

The plurality of second members 32 in FIG. 5 each have a substantially U-shaped cross-sectional shape, and are arranged in a state of being opened sideways. As described above, the second member 32 preferably has a structure having a portion whose cross-sectional area or diameter increases in the normal direction from the surface of the first member 31. For example, in the second member 32 of FIG. 5, the cross-sectional area or diameter of the intermediate portion is the smallest along the normal direction with respect to the surface of the first member 31, and the portion in contact with the first member 31 and the first member 31 It has a structure with a large cross-sectional area or diameter of the part farthest from. Further, it is also preferable that the second member 32 has a structure other than a straight pillar. The straight pillar means a columnar body in which the bottom surface and the side surface are orthogonal to each other. That is, it is also preferable that the second member 32 has a shape such as an inverted taper shape or an oblique column shape. When the second member 32 has such a structure, the resin member 34 formed by the insert molding described later is engaged with the second member 32, so that the adhesion of the resin member 34 can be improved. ..

Although the first member 31 is shown as a plate in FIG. 5, the shape of the first member 31 is not particularly limited. Further, the shape of the second member 32 is not limited to the shape shown in FIG. The components constituting the first member 31 and the second member 32 can be the same as those of the first member 11 and the second member, the seat 12, in the first embodiment.

As shown in FIG. 5, the irradiation of ionizing radiation is performed with the second member 32 arranged on a part of the surface of the first member 31. As for the method of irradiating the ionizing radiation, the method of irradiating the ionizing radiation can be the same as that of the first embodiment described above. The irradiation of ionizing radiation is performed in a state where the fluororesin of the first member 31 is melted. At this time, a part of the second member 32 may be immersed in the first member 31.

By irradiating this ionizing radiation, an insert member 33 in which the first member 31 and the second member 32 are joined can be obtained. As shown in FIG. 5, on the upper surface of the obtained insert member 33, a concave-convex shape is formed between the upper surface of the first member 31 and the second member 32. That is, the insert member 33 has a surface region 33x having an uneven shape including a portion where the second member 32 is exposed.

Next, as step B, the resin member 34 is molded on the surface region 33x of the obtained insert member 33. Specifically, as shown in FIG. 6, the insert member 33 is arranged on the mold 35. At this time, the resin member 34 is arranged so as to be laminated on the surface on the side where the second member 32 is arranged, that is, the surface region 33x having the uneven shape. The specific molding method of the resin member 34, that is, the injection method of the molten resin can be the same as that of the first embodiment described above.

By going through this step B, it is possible to obtain an insert molded body in which the resin member 34 in which the injected molten resin is solidified and the insert member 33 are composited.

(advantage)
In the manufacturing method according to the third embodiment, the second member 32 has a structure that engages with the resin member 34. As described above, the structure of the second member 32 makes it possible to further improve the adhesion to the resin to be insert-molded.

<Other Embodiments>
It should be considered that the embodiments disclosed this time are exemplary in all respects and not restrictive. The scope of the present invention is not limited to the configuration of the above embodiment, but is indicated by the scope of claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims. To.

For example, as a third embodiment, in FIGS. 5 and 6, two second members are arranged on the surface of the first member, but the second member may be one or three or more. Good. Further, the shape of the second member is not limited to the U-shape shown in FIGS. 5 and 6, and may be a columnar shape or the like.

As still another embodiment, as shown in FIG. 7, an insert member 43 having a structure in which the second member 42 is scatteredly arranged on the surface of the first member 41 can be used. At this time, as the second member 42, particles containing a resin other than metal or fluororesin as a main component can be used. Further, as shown in FIG. 8, an insert member 53 having a structure in which a plurality of linear second members 52 are arranged on the surface of the first member 51 can be used. As the second member, a metal wire or the like can be used. In the surface regions of the insert members 43 and 53 shown in FIGS. 7 and 8, a concave-convex shape is formed by the first members 41 and 51 and the second members 42 and 52. By laminating the molten resin on this surface region by insert molding, the resin member can be laminated with high shape accuracy and high adhesion. Further, even when the second member has a shape other than the sheet, it is preferable that the surface of the second member in contact with the resin member is roughened. Further, a combination of the above embodiments is also within the scope of the present invention.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to the following Examples.

<Example 1>
Using a copper alloy plate (Mitsubishi Shindoh Co., Ltd. "TAMAC194"), an insert reed was manufactured as a second member having guide pins having a diameter of 1.5 mm at both ends at a pitch of 15 mm. The obtained insert lead had a thickness of 0.25 mm, a width of 30 mm, and an arithmetic mean roughness (Ra) of 0.08 μm. As a roughening treatment, a fine uneven shape was provided on one surface of the insert reed by a laser. The arithmetic mean roughness (Ra) of the roughened surface was 3 μm. PFA was powder-coated as the first member on the surface of the insert lead that had not been roughened. The coated PFA was subjected to electron beam irradiation at 320 ° C. at 200 kGy in a nitrogen atmosphere having an oxygen concentration of 1 ppm or less to crosslink the PFA. The peel strength between the first member (crosslinked PFA) and the second member (insert lead) after electron beam irradiation was 36 N / cm. The PFA-coated lead frame, which is the insert member thus obtained, was set in the injection molding machine. An LCP (“Laberos E473i” manufactured by Polyplastics Co., Ltd .: melting point 330 ° C.) was injection-molded so as to cover the roughened surface of the PFA-coated lead frame to obtain an insert molded product. The cylinder temperature during injection molding was 340 ° C, and the mold temperature was 120 ° C.

No appearance abnormality such as wrinkles was observed on the surface of the crosslinked PFA in the obtained insert molded product, and the LCP and the crosslinked PFA were firmly integrated via the insert lead. The slidability of the crosslinked PFA in this insert molded product was evaluated by a ring-on-disk type wear test (“EFM-III 1010” manufactured by A & D Co., Ltd.) in accordance with JIS-K-7218. The measurement conditions were ring-shaped mating material S45C, ring outer diameter 11.6 mm, inner diameter 7.4 mm, dry, pressure 10 MPa, speed 50 m / min, and operating time 10 minutes. The amount of wear was 0.2 mg or less. As a result of evaluating the non-crosslinked PFA in the same manner, the evaluation was stopped due to wear of 1.6 mg or more within 1 minute.

As described above, in Example 1 above, an insert molded product containing the crosslinked fluororesin could be obtained. No abnormal appearance was observed in this insert molded product, the shape accuracy was excellent, and good adhesion between the members was confirmed. It was also confirmed that it has excellent wear resistance.

As described above, the method for manufacturing the insert molded body of the present invention is the insert molding of various electronic parts such as OA equipment, home appliances, automobiles, other transportation equipment, precision equipment, digital cameras, industrial machines, and other parts. It can be suitably used for a method for manufacturing a manufactured part.

11, 21, 31, 41, 51 First member 12 sheet (second member)
12a One surface 12b The other surface (surface area)
13, 23, 33, 43, 53 Insert member 14, 24, 34 Resin member 15, 25, 35 Mold 22, 32, 42, 52 Second member 23x, 33x Surface area

Claims (8)

In the insert member, a step of obtaining an insert member in which a first member containing a fluororesin as a main component and a second member containing a component other than the fluororesin as a main component are joined by irradiation with ionizing radiation, and by insert molding. A step of molding a resin member on a surface region including a portion where the second member is exposed is provided .
The average thickness of the first member and the second member is 1 μm or more and 5 mm or less.
The main component of the second member is a resin other than metal or fluororesin.
Resins other than the above fluororesins are selected from the group consisting of polyether ether ketone, polyimide, polyamideimide, aramid, polybenzoimidazole, LCP, urea resin, phenol resin, melamine resin, silicon resin, epoxy resin, and electron beam crosslinked polyamide. Is one of the
Fluororesin of the first member, at least one of the hydrogen atoms bonded to carbon atoms in the main chain constituting the structural unit of the polymer chain, insert molding that is substituted with an organic group having a fluorine atom or a fluorine atom How to make a body. The method for manufacturing an insert molded product according to claim 1, wherein the surface region of the insert member has an uneven shape. The second member is a sheet.
The method for producing an insert molded product according to claim 1 or 2, wherein the first member is laminated on one surface of the sheet as the second member, and the ionizing radiation is irradiated. The method for manufacturing an insert molded product according to claim 3, wherein the surface of the sheet in contact with the resin member is roughened. The second member is a woven fabric or a non-woven fabric.
The method for producing an insert molded product according to claim 1 or 2, wherein the first member is impregnated with a part of the woven fabric or the non-woven fabric as the second member, and the ionizing radiation is irradiated. The method for manufacturing an insert molded product according to claim 1 or 2, wherein one or a plurality of second members are arranged on a part of the surface of the first member, and the ionizing radiation is irradiated. The method for manufacturing an insert molded product according to any one of claims 1 to 6 , wherein the insert member is a lead frame. By irradiation with ionizing radiation, the first member containing a fluororesin as a main component and the second member containing a component other than the fluororesin as a main component are joined, and the first member and the second member are chemically bonded or mutually. The insert member is diffusing, and the resin member formed on the surface region including the exposed portion of the second member of the insert member is provided .
The average thickness of the first member and the second member is 1 μm or more and 5 mm or less.
The main component of the second member is a resin other than metal or fluororesin.
Resins other than the above fluororesins are selected from the group consisting of polyether ether ketone, polyimide, polyamideimide, aramid, polybenzoimidazole, LCP, urea resin, phenol resin, melamine resin, silicon resin, epoxy resin, and electron beam crosslinked polyamide. Is one of the
Fluororesin of the first member, at least one of the hydrogen atoms bonded to carbon atoms in the main chain constituting the structural unit of the polymer chain, insert molding that is substituted with an organic group having a fluorine atom or a fluorine atom body.

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