JP6902950B2 - 金属樹脂複合成形品およびその製造方法 - Google Patents
金属樹脂複合成形品およびその製造方法 Download PDFInfo
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- JP6902950B2 JP6902950B2 JP2017140649A JP2017140649A JP6902950B2 JP 6902950 B2 JP6902950 B2 JP 6902950B2 JP 2017140649 A JP2017140649 A JP 2017140649A JP 2017140649 A JP2017140649 A JP 2017140649A JP 6902950 B2 JP6902950 B2 JP 6902950B2
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- metal plate
- metal
- resin
- molded product
- composite molded
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2274/00—Thermoplastic elastomer material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/748—Releasability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
- B32B2457/202—LCD, i.e. liquid crystal displays
Description
最近のスマートフォンの筐体のような薄型が求められる金属板では、この変形を抑制することが課題となっていた。
また、フープ成形のインサート端子のように、金属をロール状に巻いて用いる場合には、金属板が厚すぎてはロール状に巻き取ることができず、仮に巻くことができても、厚い金属板を無理に巻き取ると、その際に金属板にかかった負荷が内部歪として残留し、金属板の強度低下や変形が生じ、インサート成形品としての接合強度や気密性を低下させるといった問題が発生するため、このような用途においては、巻取り性の面からやはり厚さ500μm以下程度の金属薄板が必要となり、そのような薄肉の金属板のレーザー加工時の変形を抑制することが課題となっていた。
(1) 金属板に樹脂組成物をインサート成形した金属樹脂複合成形品であって、該金属板は、厚さHが500μm以下であり、該金属板の該樹脂組成物がインサートされる表面には溝が形成されており、該溝は、幅Yが30〜300μm、深さXが該金属板の厚さHの24%以下、該幅Yに対する該深さXの割合X/Yが0.1〜2.5である金属樹脂複合成形品。
本発明の金属樹脂複合成形品は、金属板に樹脂組成物をインサート成形した金属樹脂複合成形品であって、該金属板は、厚さHが500μm以下であり、該金属板の該樹脂組成物がインサートされる表面には溝が形成されており、該溝は、幅Yが30〜300μm、深さXが該金属板の厚さHの24%以下、該幅Yに対する該深さXの割合X/Yが0.1〜2.5であることを特徴とする。
本発明に使用される金属板としては、アルミニウム、マグネシウム、ステンレス鋼、銅、チタン等を例示することができる。また、金属板は、金属合金から構成されてもよい。また、金属材料の表面には、陽極酸化処理等の表面処理や塗装がされていてもよい。軽量、強度の点からアルミニウム、マグネシウム、銅、チタンが好ましく、端子等の導電性が必要とされる用途においてはアルミニウム、銅がより好ましく、銅が特に好ましい。また、携帯端末筐体等の薄肉での剛性が要求される用途においてはマグネシウム、チタンが好ましく、チタンが特に好ましい。
本発明では、金属板の厚みHが500μm以下である場合に有用である。金属膜の厚みHの下限は、強度的に100μm以上であることが好ましい。
本発明においては、金属板の表面に形成される溝は、幅Yが30〜300μm、深さXが該金属板の厚さHの24%以下、該幅Yに対する該深さXの割合X/Yが0.1〜2.5となるように形成される。
本発明に係る溝は、レーザーによって形成される。具体的には、レーザーを照射して、金属表面を堀加工及び溶融させ再凝固させる条件にて溝を形成する。具体的にパルス波のレーザー光を照射する場合を例に説明する。図1には金属表面へのレーザー光の照射パターンの例を記載する。金属表面上でレーザーが照射された部分に溝が形成される。なお、図1中の白抜き矢印は、レーザーの走査方向を表す。
上記のようにして得られた金属板の表面に、レーザーを用いて、溝を形成する。溝を形成する位置や、溝の範囲の大きさは、樹脂が形成される位置等を考慮して決定される。
本発明で使用される樹脂組成物は、特に限定されず、従来公知の熱可塑性樹脂を含む熱可塑性組成物を使用することができる。
本発明の金属樹脂複合成形品は、上記金属板と、金属板の表面の少なくとも一部に形成される樹脂組成物とを備える。
金属樹脂複合成形品の製造方法の具体的な工程は特に限定されず、溶融した熱可塑性樹脂組成物を溝の凹凸に入り込ませることで、樹脂と金属板とを複合化させるものであればよい。
<金属樹脂複合成形品の特性>
例えば、本発明の金属樹脂複合成形品は、導電性発熱部と絶縁部と導電性放熱部とを備え、導電性発熱部から絶縁部を介して導電性放熱部へと熱を伝達して放熱を行う放熱構造体において用いることができる。
実施例及び比較例で使用した金属樹脂複合成形品(インサート成形体)の模式図を図3に示した。(a)は上面図であり、(b)は斜視図であり、(c)は断面図である。(b)の上部は金属板であり、下部がインサート樹脂である。
このインサート成形体を以下の方法で製造した。なお、図中の寸法の単位はmmである。
東洋精機(株)製キャピログラフを用い、キャピラリーとして1mmφ×20mmL/フラットダイを使用し、所定のバレル温度、せん断速度1000/秒での溶融粘度を測定した。上記のバレル温度は、310℃に設定した。
レーザーマーカMD−V9900(キーエンス社製、レーザータイプ:YV04レーザー、発信波長:1064nm、最大定格出力:13W(平均))を用い、出力90%、周波数40kHz、走査速度1000mm/sにて、接合予定面の金属表面に、表1及び表2に示す深さと幅で、図3(b)に示すような同心円状になるように溝を形成した。なお、レーザー光のスポット径と走査回数は、溝の深さと幅に応じ適宜調整した。例えば幅50μm、深さ70μmの場合は、スポット径を50μmに調整し、走査回数を300回とした。
ここで溝の本数は、図3に示す試験片において樹脂と金属が接触する領域(接合予定面)の面積のうち、溝を形成する凹凸の凹部と凸部の投影面積がそれぞれ同等になるよう、凹部の幅と凸部の幅が等間隔(ハッチング幅が溝の幅Yの2倍)となるように設定した。すなわち、樹脂と金属が接触する領域の外周(直径30mm)の半径15mmと、内周(直径20mm)の半径10mmとの間の5mm幅の中に形成される溝の本数は、概ね5mm÷(幅Y×2)となる。
[成形条件]
成形機:ソディックTR−40VR(縦型射出成形機)
シリンダー温度:320℃
金型温度:150℃
射出速度:100mm/s
保圧力:49MPa×5秒
上記の方法で作成した金属樹脂複合成形品について、接合部分の接合強度及び剥離後の破壊形態を評価した。具体的な評価方法は以下の通りである。
[変形]
レーザー照射後の金属板を目視で観察し、反り等の著しい変形が見られるものは×、そうでないものは○として評価した。結果を表1及び表2に示す。
[接合性(気密性)]
接合性の評価は、上記の方法で作製した金属樹脂複合成形体5について、以下の方法により気密性を測定した。図4は、気密試験機Eを用いた気密性評価の方法を示す縦断面図である。気密試験機Eは、気密試験機本体7と気密試験機蓋6とを備える。Oリング5を介して金属樹脂複合成形体試験片2を気密試験機本体7に取り付け、金属樹脂複合成形体試験片2の下部を封止した。その後、気密試験機蓋6を金属樹脂複合成形体試験片2の樹脂部材4上に載せてクランプした。
△:1〜2回で気泡の漏れが確認された場合、気密性が中程度であると評価した。
×:3回とも漏れが確認された場合、気密性が不良であると評価した。
フープ成形に用いる場合を想定し、実施例と比較例で用いた各厚さの金属板を、レーザー照射を行う前の状態で20mm×50mmの板状に裁断し、長手方向が円周方向になるように、曲率半径40mmの円柱に巻き付けて10秒間保持した後、保持時に外側になっていた面を下にして定盤上に載置し、歪による反りの発生を目視で確認した。
図5には、厚さ400μmの金属板を用いた場合について、請求項1の各数値規定を満足する範囲をハッチングした枠で示し、板厚400μmに該当する実施例と比較例を示した。
1 金属板にレーザーで形成された溝
2 金属板が樹脂組成物でインサート成形された試験片
3 レーザー加工された金属板
4 樹脂組成物からなる成形体=樹脂部材
5 Oリング
6 気密試験機蓋
7 気密試験機本体
8 圧力
9 ライン
10 蒸留水
E 気密試験機
a、c、d 接合(気密性)不良発生領域
b 変形発生領域
Claims (2)
- 金属板に樹脂組成物をインサート成形した金属樹脂複合成形品であって、該金属板は、厚さHが450μm以下であり、該金属板の該樹脂組成物がインサートされる表面には溝が形成されており、該溝は、幅Yが30〜300μm、深さXが該金属板の厚さHの24%以下、該幅Yに対する該深さXの割合X/Yが0.1〜2.5である金属樹脂複合成形品。
- 厚さHが450μm以下であるロール状の金属板に、樹脂組成物をインサート成形して金属樹脂複合成形品を製造する方法であって、該金属板の表面に該樹脂組成物をインサートする溝を形成する工程を有し、該溝を、幅Yが30〜300μm、深さXが該金属板の厚さHの24%以下、該幅Yに対する該深さXの割合X/Yが0.1〜2.5とする金属樹脂複合成形品の製造方法。
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PCT/JP2018/027081 WO2019017428A1 (ja) | 2017-07-20 | 2018-07-19 | 金属樹脂複合成形品およびその製造方法 |
US16/632,257 US11697232B2 (en) | 2017-07-20 | 2018-07-19 | Metal resin composite-molded article and method for manufacturing same |
EP18835735.4A EP3656528A4 (en) | 2017-07-20 | 2018-07-19 | MOLDED METAL RESIN COMPOSITE ARTICLE AND METHOD FOR MANUFACTURING THEREOF |
CN201880060255.3A CN111093932B (zh) | 2017-07-20 | 2018-07-19 | 金属树脂复合成型品及其制造方法 |
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CN112123789A (zh) * | 2020-09-15 | 2020-12-25 | 哈尔滨工业大学(威海) | 一种金属/碳纤维增强热塑复合材料激光连接方法 |
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JP2005342922A (ja) * | 2004-05-31 | 2005-12-15 | Polyplastics Co | ダイヤモンド状炭素被膜を有する金型、それを用いた成形方法 |
JPWO2009151099A1 (ja) * | 2008-06-12 | 2011-11-17 | 日本軽金属株式会社 | アルミ・樹脂射出一体成形品及びその製造方法 |
JP5577707B2 (ja) * | 2010-01-12 | 2014-08-27 | 日本軽金属株式会社 | アルミニウム合金板と樹脂部材とのレーザー接合方法 |
JP2011143457A (ja) * | 2010-01-15 | 2011-07-28 | Tyco Electronics Japan Kk | レーザ溶接構造 |
CN102933656B (zh) * | 2010-06-09 | 2014-10-29 | 胜技高分子株式会社 | 聚对苯二甲酸丁二醇酯树脂组合物、金属复合部件、及金属复合部件的制造方法 |
WO2012071259A1 (en) * | 2010-11-23 | 2012-05-31 | Taiwan Green Point Enterprises Co., Ltd. | Method and structure of binding plastic and metal material together |
JP2013052669A (ja) * | 2010-12-28 | 2013-03-21 | Daicel Corp | 複合成形体の製造方法 |
JP6055529B2 (ja) * | 2010-12-28 | 2016-12-27 | 株式会社ダイセル | 複合成形体の製造方法 |
KR102027805B1 (ko) * | 2011-10-13 | 2019-10-02 | 필립스 아이피 벤쳐스 비.브이. | 복합 금속 표면 |
JP5848104B2 (ja) * | 2011-11-21 | 2016-01-27 | 株式会社ダイセル | 複合成形体の製造方法 |
EP2832526A4 (en) * | 2012-03-29 | 2015-03-25 | Teijin Ltd | METHOD FOR MANUFACTURING JOINT ELEMENT AND JOINT ELEMENT |
JP2014004802A (ja) * | 2012-06-27 | 2014-01-16 | Shin Kobe Electric Mach Co Ltd | 金属部材を一体化した樹脂成形品とその製造法 |
JP5798535B2 (ja) * | 2012-09-07 | 2015-10-21 | ダイセルポリマー株式会社 | 複合成形体の製造方法 |
JP5843750B2 (ja) | 2012-12-14 | 2016-01-13 | ポリプラスチックス株式会社 | 金属部品の製造方法、及び複合成形体 |
CN103862619A (zh) * | 2012-12-14 | 2014-06-18 | 宝理塑料株式会社 | 金属树脂复合成型体用嵌件金属构件和金属树脂复合成型体 |
JP2014133407A (ja) * | 2012-12-14 | 2014-07-24 | Polyplastics Co | 金属樹脂複合成形体用インサート金属部材及び金属樹脂複合成形体 |
KR101641652B1 (ko) * | 2013-02-12 | 2016-07-21 | 포리프라스틱 가부시키가이샤 | 홈붙이 수지 성형품 |
JP5701414B1 (ja) * | 2013-03-26 | 2015-04-15 | ダイセルポリマー株式会社 | 複合成形体の製造方法 |
JP6259644B2 (ja) * | 2013-04-24 | 2018-01-10 | 三井化学株式会社 | 金属/樹脂複合構造体 |
CN104227930B (zh) * | 2013-06-12 | 2019-02-22 | 宝理塑料株式会社 | 金属树脂复合成型体及其制造方法 |
JP6057216B2 (ja) * | 2013-08-30 | 2017-01-11 | 新生化学工業株式会社 | インサート成形方法及びインサート成形品 |
CN105452526B (zh) * | 2013-10-07 | 2017-09-19 | 三菱工程塑料株式会社 | 树脂组合物、树脂成型品和树脂成型品的制造方法 |
WO2015087720A1 (ja) * | 2013-12-13 | 2015-06-18 | 住友ベークライト株式会社 | 金属樹脂複合体 |
CN105829452B (zh) * | 2013-12-20 | 2019-06-18 | 住友电木株式会社 | 热固化性树脂组合物及金属树脂复合体 |
CN104742437B (zh) * | 2013-12-31 | 2018-05-08 | 比亚迪股份有限公司 | 一种金属树脂复合体及其制备方法 |
EP3305519B1 (en) * | 2015-06-03 | 2021-06-30 | Kaneka Corporation | Metal resin composite |
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CN111093932B (zh) | 2022-01-14 |
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US11697232B2 (en) | 2023-07-11 |
US20200223113A1 (en) | 2020-07-16 |
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