JPWO2009116484A1 - 亜鉛系鍍金鋼板と被着材の接合体及びその製造方法 - Google Patents
亜鉛系鍍金鋼板と被着材の接合体及びその製造方法 Download PDFInfo
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- JPWO2009116484A1 JPWO2009116484A1 JP2010503860A JP2010503860A JPWO2009116484A1 JP WO2009116484 A1 JPWO2009116484 A1 JP WO2009116484A1 JP 2010503860 A JP2010503860 A JP 2010503860A JP 2010503860 A JP2010503860 A JP 2010503860A JP WO2009116484 A1 JPWO2009116484 A1 JP WO2009116484A1
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- Prior art keywords
- zinc
- steel sheet
- plated steel
- based plated
- adherend
- Prior art date
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- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 150000003751 zinc Chemical class 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/51—One specific pretreatment, e.g. phosphatation, chromatation, in combination with one specific coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14008—Inserting articles into the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/44—Joining a heated non plastics element to a plastics element
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/004—Preventing sticking together, e.g. of some areas of the parts to be joined
- B29C66/0042—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/026—Chemical pre-treatments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/03—After-treatments in the joint area
- B29C66/034—Thermal after-treatments
- B29C66/0344—Annealing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
- B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined
- B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
- B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
- B29C66/7311—Thermal properties
- B29C66/73111—Thermal expansion coefficient
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
- B29C66/7311—Thermal properties
- B29C66/73115—Melting point
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
- B29C66/7315—Mechanical properties
- B29C66/73151—Hardness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
- B29C66/7316—Surface properties
- B29C66/73161—Roughness or rugosity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73775—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being crystalline
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7428—Transition metals or their alloys
- B29C66/74283—Iron or alloys of iron, e.g. steel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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Abstract
Description
本発明者らは、アミン系化合物の金属合金表面への化学吸着なしに、要するに特段の発熱反応や何らかの化学反応の助力を得ることなしに、射出接合が可能な条件を発見した。即ち、アルミニウム合金以外の金属合金についても、その金属合金と熱可塑性樹脂を射出接合によって強固に接合することができる条件を発見し、この条件に基づく射出接合のメカニズムを「新NMT(Nano molding technologyの略)」と称した。
第1の条件は、金属合金表面が、化学エッチング手法によって1〜10μm周期の凹凸で、その凹凸高低差がその周期の半分程度まで、即ち0.5〜5μmまでの粗い粗面になっていることである。ただし、実際には、前記粗面で正確に全表面を覆うことはバラツキがあり、一定しない化学反応では難しく、具体的には、粗度計で見た場合に0.2〜20μm範囲の不定期な周期の凹凸で、且つその最大高低差が0.2〜5μmの範囲である粗度曲線が描けること、又は、最新型のダイナミックモード型の走査型プローブ顕微鏡で走査して、JIS規格(JISB0601:2001)でいう平均周期、即ち山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmである粗度面であれば、前記で示した粗度条件を実質的に満たしたものと考えている。本発明者等は、理想とする粗面の凹凸周期が前記したように、ほぼ1〜10μmであるので、分かり易い言葉として「ミクロンオーダーの粗度を有する表面」と称した。
次に、樹脂側の条件を説明する。樹脂としては、硬質の高結晶性の熱可塑性樹脂であって、これに適切な別ポリマーをコンパウンドする等して、急冷時での結晶化速度を遅くした物が使用できる。実際には、結晶性の硬質樹脂であるPBTやPPSに適切な別ポリマー及びガラス繊維等をコンパウンドした樹脂組成物が使用できる。
上記金属合金及び樹脂を使用して、一般の射出成形機、射出成形金型によって射出接合できるが、この過程を前述の「新NMT」に従って説明する。射出した溶融樹脂は、融点よりも150℃程度温度が低い金型内に導かれるが、この流路で冷やされ、融点以下の温度になっているとみられる。即ち、溶融した結晶性樹脂が急冷された場合、融点以下になったとしてもゼロ時間で結晶が生じ固体に変化することはない。要するに、融点以下ながら溶融している状態、即ち過冷却状態がごく短時間存在する。前述したように、PBTやPPSに特殊なコンパウンドを行うことによって、この過冷却時間を少し長くすることが可能である。これを利用して大量の微結晶が生じることによる粘度の急上昇が起こる前に、ミクロンオーダーの粗度を有する金属表面の凹部にその微結晶が侵入できるようにした。侵入後も冷え続けるので、これに伴い微結晶の数が急激に増えて粘度は急上昇する。しかし、凹部の奥底まで樹脂が到達できるか否かは凹部の大きさや形状にも依存する。
本発明者らは、接着剤接合に関しても「新NMT」が応用できると考え、類似理論による高強度の接着が可能であるかを確認した。そして、市販の汎用の1液性エポキシ系接着剤を使用し、金属合金の表面構造を工夫することで、より接着力の高い接合体を得ようと試みた。
[1.亜鉛系鍍金鋼板]
本発明の亜鉛系鍍金鋼板には、溶融亜鉛鍍金鋼板、合金化溶融亜鉛鍍金鋼板、電気亜鉛鍍金鋼板、電気亜鉛鍍金鋼材、溶融亜鉛アルミニウム合金鍍金鋼板(例えば、溶融Zn−55%Al合金鍍金鋼板のガルバリウム鋼板、他に溶融Zn―11%Al―3%Mg合金鍍金鋼板などがある)が含まれる。実際に流通しているのは前記した亜鉛系鍍金鋼板に各種の化成処理や後処理をした物が大部分である。即ち、前記素材群は、主として表面亜鉛の酸化や炭酸化物皮膜による内部保護作用と、これが破られた場合も亜鉛自身の犠牲腐食作用があって芯部鋼材の腐食を遅らせることが出来る優れた耐食性鋼材である。しかし、これらがそのまま使用されることは少なく、多くはクロメート処理やノンクロメート処理等の化成処理か又はクロム系化合物を含んだ有機物塗膜が塗布されるなどされており、亜鉛鍍金層自体を保護している。そして化成処理された亜鉛系鍍金鋼板の多くは、油剤を塗布されてプレス加工時の潤滑性を確保した鋼材となっている。要するに、用途や二次加工ユーザーの要望によって種々の表面処理品が大手素材メーカーから供給されている。又、亜鉛系鍍金鋼板メーカー自身が塗装まで行ってカラー鋼板やカラートタンというプレコート鋼板まで製造し市販している物も多い。
通常、「新NMT」「NAT」理論に従う金属合金を得るには、即ち、前述した(1)〜(3)の条件を満足する表面にするには、基本的に、a.脱脂、b.化学エッチング、c.微細エッチング、d.表面硬化の4工程を経る。使用する金属合金種により、前記4工程のうち、「a.脱脂」が省略される場合もあるし、「b.化学エッチング」が「c.微細エッチング」を兼ねる場合もあるし、「b.化学エッチング」が「c.微細エッチング」も「d.表面硬化」も兼ねる場合もある。又、その逆に、「d.表面硬化」として行う化成処理が「b.化学エッチング」「c.微細エッチング」を兼ねる場合もある。何れにしても、本発明者らが実施した化学処理法の基本は、各工程の目的を考えながら「a」〜「d」の具体的方法を考察して実施し、その評価をし、結果的に省略可能な工程があれば省略するというやり方で工程を詰めるものであった。
この樹脂組成物は、射出成形により、前記亜鉛系鍍金鋼板に直接的に接合される。結晶性の樹脂であるPBTを主成分とする第1樹脂組成物、PPSを主成分とする第2樹脂組成物、又は、芳香族ポリアミドを主成分とする第3樹脂組成物をいう。この第1樹脂組成物の樹脂分は、PBTを主成分としポリエチレンテレフタレート(以下「PET」という)及び/又はポリオレフィン系樹脂を従成分とする樹脂組成物である。また、第2樹脂組成物の樹脂分はPPSを主成分としポリオレフィン系樹脂を従成分とする樹脂組成物である。又、第3樹脂組成物の樹脂分は、芳香族ポリアミドを主成分とし脂肪族ポリアミドを従成分とする樹脂組成物である。
本発明に係る複合体製造方法は、金属合金を金型にインサートした上で行う射出成形法であり、以下のように行う。射出成形用金型を用意し、その金型に亜鉛系鍍金鋼板からなる形状物をインサートし、金型を閉じ、改良したPBT、改良したPPS、又は改良した芳香族ポリアミド系の熱可塑性樹脂組成物を射出し、固化した後に金型を開き離型することにより複合体の製造を行う。
前述した表面処理を施した亜鉛系鍍金鋼板は、表面処理前と比較して鍍金層が薄くなっており、その上に化成皮膜層が形成されている。この様な鋼板を射出成形金型にインサートして射出接合した場合、鋼板が金型に挟まれて搾られ曲がることも十分あるので、そのようなとき、化成皮膜層が割れ、且つ、鍍金層が引き伸ばされて更に薄くなる可能性がある。それ故、射出接合により得られた複合体については、一体化後に再度の化成処理をするのも好ましい。短時間で複合体に対して再度の化成処理を行い、早急に乾燥すれば接合力を減じることは少ない。
圧融着用の樹脂組成物は、硬質の高結晶性樹脂を主成分とする樹脂組成物が使用できる。「新NMT」での圧融着では、樹脂種としてPBT、PPS、芳香族ポリアミド、脂肪族ポリアミド、液晶ポリマー、ポリエーテルエーテルケトン(以下、「PEEK」という)、等が使用できるとしているが、PEEKについては融点が400℃近くと高すぎて亜鉛系鍍金鋼板での圧融着には好ましくない。亜鉛の融点に近いからである。又、前述した射出接合用の熱可塑性樹脂、即ち射出接合用に改良したPBT、PPS、芳香族ポリアミド系の樹脂も勿論使用できる。要するに、前述した射出接合用の熱可塑性樹脂よりも範囲が広く、硬質の高結晶性樹脂であれば使用できる。特に、その融点が高過ぎないことから、PBT、PPS、ポリアミド樹脂等が好ましい。
圧融着による複合体製造法に使用する樹脂組成物の樹脂分は硬質の高結晶性樹脂であって、具体的には、PBT、PPS、芳香族ポリアミド、脂肪族ポリアミド、又は液晶ポリマー等が好ましい。射出接合で好適に使用できるとした、改良したPBT、改良したPPS、及び改良した芳香族ポリアミド系の樹脂組成物もこれらの範疇に入り、勿論使用に好ましい。ガラス繊維、その他の充填材をコンパウンドして樹脂組成物とし、これを原料にして射出成形機にかけて樹脂成形品をまず製作する。
塗布時に液状であり、且つ巨大分子(ゲル化分子)が少ない熱硬化型接着剤が「NAT」理論における接合で望まれるものである。更に具体面から言えば、金属合金(亜鉛系鍍金鋼材)表面上の数μm周期の凹部に侵入し、更にその凹部内に存在する数十nm周期の超微細凹凸の隙間にもある程度侵入しなければならない。それ故、後述する減圧/常圧戻しのサイクルを加える際に、液の粘度は高くとも20Pa秒以下であり、好ましくは十数Pa秒以下であることを要する。
一方、2液性熱硬化型接着剤を前述の表面処理をした金属合金に使用する場合、接合力は向上するものの、殆どは明確な効果は奏しない。2液性接着剤では主液に硬化剤成分を加えて混合した瞬間からゲル化が始まるものが殆どで、ゲル化が進むと(2)超微細凹凸の隙間に樹脂成分の侵入が少なくなる。要するに、2液性接着剤を使用した場合は、硬化剤を混合した後の経過時間によって接着力が変化することが多く、安定性や再現性に劣ることがあるのが好ましくない。ただし、前述したように、一般的には2液性接着剤とされている酸無水物を硬化剤とするエポキシ系接着剤であっても、ゲル化が始まるまでの時間が一定時間あり、且つゲル化温度が高い場合は使用に好ましい。このような接着剤は実質的には1液性接着剤と同じ扱いになる。
上述したように、エポキシ系、フェノール系、及び不飽和ポリエステル系の接着剤が好ましく使用できる。エポキシ系、フェノール系の双方は優れた接着能を有する物が多数市販されている。塗布時に液体であることが必要である。常温で固体状である高粘度接着剤も50〜80℃にすれば十数Pa秒の液体と言えるレベルの粘度にまで下がる。このような現象を利用するのが好ましい。このような高粘度の接着剤として代表的なものはエポキシ系接着剤であるので、エポキシ系接着剤を使用するときの要点について述べる。
本発明は、亜鉛系鍍金鋼板と被着材(金属合金又は樹脂成形品若しくはFRP)を強固に接合する技術であり、種々の分野に適用可能である。具体的には建材、屋外機器、建設機械部品、一般機械の部品製造等に適する技術であり、これらの製造において新しい設計方法を可能とする。本発明は亜鉛系鍍金鋼板に係る部品製造の基礎技術となりうるものであり、応用分野は上記以外にも存在すると考えられ、各種部品の性能向上、生産性向上に寄与するものである。
[射出接合の方法]
図1及び図2は熱可塑性樹脂の射出接合に関する図であり、図1は、後述する実験例で使用する射出成形金型の断面を模式的に示した断面図である。図1は、金型が閉じ射出成形される状態を示している。図2は、亜鉛系鍍金鋼板と射出成形金型で成形された樹脂成形品からなる複合体7の外観を示す外観図である。この射出成形金型は、可動側型板2と固定側型板3で構成され、固定側型板3側にピンポイントゲート5、ランナー等からなる樹脂射出部が構成されている。
図3、図4、図5、図6、図7は亜鉛系鍍金鋼板片と樹脂成形品の圧融着に関する図であり、図3は後述する実験例で使用する熱可塑性樹脂の成形品の形状を示した図である。図4は、前記樹脂成形品がボス形状の場合であって、ボス底部中央が0.1mm程度外に突き出した形状になるように形状設計した例を示している。要するに、充填型ボス形状品を射出成形すると、樹脂組成物の成形収縮によって必ずボス底部の中央がへこむ。底のへこんだ物は圧融着に望ましくない為、底中央部が突き出るように予め設計すべきことを示したものである。図4のように成形はピンゲートによって為されてよいが、結果的に、ボス底中央が0.1mm程度張り出しているか又は悪くとも平面であることが好ましい。
図11は、亜鉛系鍍金鋼板片同士(61、62)を接着剤で接合することにより得られた接合体60の形状を示したものであり、後述する実験例で使用するものである。亜鉛系鍍金鋼板片61、62は、いずれも45mm×18mmであり、接着面積(図11中の斜線部分63の面積)は0.5〜0.6cm2程度である。この接合体60を引っ張り破断し、せん断破断力を測定する。接合体60を構成する片方を亜鉛系鍍金鋼板片ではなく、異なる金属合金としても良い。その金属合金が、「NAT」に基づいて表面処理されたアルミニウム合金、マグネシウム合金、銅合金、チタン合金、ステンレス鋼、又は一般鋼材であれば、特に強力な接合力を生じる。
図9に、亜鉛系鍍金鋼板片とCFRP片の複合体の焼成治具41を示す。図10には、焼成治具41の使用により得られる亜鉛系鍍金鋼板片51とCFRP片52の複合体50の形状を示す。焼成治具41において、金型本体42は、上面が開放されており長方体状に金型凹部43が形成されている。この底部には金型貫通孔44が形成されている。
[PPSの溶融粘度測定]
直径1mm、長さ2mmのダイスを装着した高化式フローテスター「CFT−500(株式会社 島津製作所製)」にて、測定温度315℃、荷重98N(10kgf)の条件下で溶融粘度の測定を行う。
(a)X線光電子分析装置によるXPS観察
試料にX線を照射することによって試料から放出してくる光電子のエネルギーを分析し、 元素の定性分析等を行う光電子分析装置を用いて亜鉛系鍍金鋼板表面の分析を行った(XPS観察)。この光電子分析装置は、数μm径の表面を深さ数nmまでの範囲で観察する形式の「AXIS−Nova」(クレイトス/株式会社 島津製作所製)を使用した。
亜鉛系鍍金鋼板の表面観察のために電子顕微鏡を用いた。この電子顕微鏡は、走査型(SEM)の電子顕微鏡「S−4800」(株式会社 日立製作所製)」及び「JSM−6700F」(日本電子株式会社製)を使用し、1〜2KVにて観察した。
亜鉛系鍍金鋼板の表面観察のために走査型プローブ顕微鏡を用いた。この顕微鏡は、先端を尖らせた探針を用いて、物質の表面をなぞるように動かして表面状態を拡大観察する走査型プローブ顕微鏡「SPM−9600(株式会社 島津製作所製)」である。
引っ張り試験機で複合体を引っ張ってせん断力を付加し、複合体が破断するときの破断力をせん断破断力として測定した。引っ張り試験機として「MODEL−1323(アイコーエンジニアリング株式会社(日本国)製)」を使用し、引っ張り速度10mm/分でせん断破断力を測定した。
攪拌機を装備する50リットルオートクレーブに、硫化ナトリウム(九水和物)Na2S・9H2Oを6214g及びN−メチル−2−ピロリドンを17000g仕込み、窒素気流下で攪拌しながら徐々に205℃まで昇温して、1355gの水を留去した。この系を140℃まで冷却した後、p−ジクロロベンゼンを7160g及びN−メチル−2−ピロリドンを5000g添加し、窒素気流下に系を封入した。この系を2時間かけて225℃に昇温し、225℃にて2時間重合させた後、30分かけて250℃に昇温し、さらに250℃にて3時間重合を行った。重合終了後、室温まで冷却しポリマーを遠心分離機により分離した。分離後の固形分について温水でポリマーを繰り返し洗浄し、100℃で一昼夜乾燥することにより、溶融粘度が280ポイズのPPS(以下、PPS(1)と記す。)を得た。
調整例1で得られたPPS(1)を、酸素雰囲気下250℃で3時間硬化させたものをPPS(3)とした。得られたPPS(3)の溶融粘度は、1800ポイズであった。
調整例1で得られたPPS(2)7.2kgとグリシジルメタクリレート−エチレン共重合体「ボンドファーストE(住友化学株式会社製)」0.8kgをあらかじめタンブラーにて均一に混合した。その後、二軸押出機「TEM−35B」にて、平均繊維径9μm、繊維長3mmのガラス繊維「RES03−TP91」をサイドフィーダーから添加量が20質量%となるように供給しながら、シリンダー温度300℃で溶融混練してペレット化したPPS組成物(3)を得た。得られたPPS組成物(3)を175℃で5時間乾燥した。
調整例1で得られたPPS(2)4.0kgとエチレン−アクリル酸エステル−無水マレイン酸三元共重合体「ボンダインTX8030」4.0Kgをあらかじめタンブラーにて均一に混合した。その後、二軸押出機「TEM−35B」にて、平均繊維径9μm、繊維長3mmのガラス繊維「RES03−TP91」をサイドフィーダーから添加量が20質量%となるように供給しながら、シリンダー温度300℃で溶融混練してペレット化したPPS組成物(4)を得た。得られたPPS組成物(4)を175℃で5時間乾燥した。
PBT樹脂「トレコン1100S(東レ株式会社製)」4.5KgとPET樹脂「TR−4550BH(帝人化成株式会社製)」0.5Kgをタンブラーにて均一に混合した。その後、二軸押出機「TEM−35B」にて、平均繊維径9μm、繊維長3mmのガラス繊維「RES03−TP91」をサイドフィーダーから添加量が30質量%となるように供給しながら、シリンダー温度270℃で溶融混練し、ペレット化したPBT系樹脂組成物を得た。これを140℃で3時間乾燥したものをPBT組成物(1)とした。
PBT樹脂「トレコン1401X31(東レ株式会社製)」6.0kgとエチレン−アクリル酸エステル−無水マレイン酸三元共重合体「ボンダインTX8030」0.7Kg、エポキシ樹脂「エピコート1004」0.15kgをあらかじめタンブラーにて均一に混合した。その後、二軸押出機「TEM−35B」にて、平均繊維径9μm、繊維長3mmのガラス繊維「RES03−TP91」をサイドフィーダーから添加量が30質量%となるように供給しながら、シリンダー温度270℃で溶融混練してペレット化したPBT組成物(2)を得た。得られたPBT組成物(2)を150℃で5時間乾燥した。
PBT樹脂「トレコン1401X31」6.0kgとPET樹脂「TR−4550BH」0.5Kg、エチレン−アクリル酸エステル−無水マレイン酸三元共重合体「ボンダインTX8030」0.5Kg、エポキシ樹脂「エピコート1004」0.1kgをあらかじめタンブラーにて均一に混合した。その後、二軸押出機「TEM−35B」にて、平均繊維径9μm、繊維長3mmのガラス繊維「RES03−TP91」をサイドフィーダーから添加量が30質量%となるように供給しながら、シリンダー温度270℃で溶融混練してペレット化したPBT組成物(3)を得た。得られたPBT組成物(3)を150℃で5時間乾燥した。
0.4mm厚の油剤塗布及びクロメート処理済み溶融亜鉛鍍金鋼板「Z18(日鐵住金建材株式会社製)」を入手し、これを18mm×45mmの長方形片に切断し、多数の亜鉛鍍金鋼板片を作成した。槽にアルミニウム用脱脂剤「NE−6(メルテックス株式会社製)」7.5%を含む水溶液を用意して液温75℃とし、この水溶液を脱脂用水溶液とした。亜鉛鍍金鋼板片5個を脱脂槽で7分浸漬し、イオン交換水で十分に水洗し、90℃とした熱風乾燥機内に15分置いて乾燥した。
実験例1で使用したものと同じ溶融亜鉛鍍金鋼板「Z18」を18mm×45mmの長方形片に切断し、多数の亜鉛鍍金鋼板片を作成した。槽にアルミニウム用脱脂剤「NE−6」7.5%を含む水溶液を用意し、今回は実験例1より液温が低い50℃とし、この水溶液を脱脂用水溶液とした。亜鉛鍍金鋼板片を脱脂槽に2分浸漬し、イオン交換水でよく水洗し、90℃の熱風乾燥機にて15分置き乾燥した。
実験例1で使用したものと同じ溶融亜鉛鍍金鋼板「Z18」を18mm×45mmの長方形片に切断し、多数の亜鉛鍍金鋼板片を作成した。槽にアルミ用脱脂剤「NE−6」7.5%を含む水溶液を用意して液温75℃とし、この水溶液を脱脂用水溶液とした。また別の槽に、55℃とした正リン酸を1.2%、亜鉛華を0.21%、珪弗化ナトリウムを0.16%、及び塩基性炭酸ニッケルを0.23%含むリン酸亜鉛型化成処理液を用意した。
実験例1で使用したのと同じ溶融亜鉛鍍金鋼板「Z18」を18mm×45mmの長方形片に切断し、多数の亜鉛鍍金鋼板片を作成した。槽にアルミ用脱脂剤「NE−6」7.5%を含む水溶液を用意して液温75℃とし、この水溶液を脱脂用水溶液とした。また別の槽に、正リン酸を1.2%、硝酸亜鉛を0.2%、硝酸カルシウムを0.3%、及び塩基性炭酸ニッケルを0.2%含む65℃としたリン酸亜鉛カルシウム型化成処理液を用意した。
実験例4と同様の実験を行った。但し、異なるのは最後の化成処理であって、実験例4で使用した自作のリン酸亜鉛カルシウム型化成処理液に代えて市販のリン酸亜鉛カルシウム型化成処理液を使用した。本実験例5では「パルボンド880(日本パーカライジング株式会社製)」を使用した。「パルボンド880」の通常の使用条件(鋼材の化成処理時での使用条件)は液温80〜90℃として鋼材を2分程度浸漬するものだが、本発明ではこれより遥かに温和な条件で使用した。具体的には、液温65℃で浸漬時間1分とした。
実験例3と同様の実験を行った。但し、異なるのは化成処理であって、実施例3で使用したリン酸亜鉛系化成処理液に代え、1.2%水和硝酸クロムを1.2%、三酸化クロムを0.3%、正リン酸を1.5%、塩基性炭酸ニッケルを0.033%含むクロメート処理型の水溶液を40℃として使用した。
0.6mm厚の溶融亜鉛アルミニウム合金鍍金鋼板(通称ガルバリウム鋼板)「GL−AZ150(日新製鋼株式会社製)」を18mm×45mmの長方形片に切断し、多数の亜鉛アルミニウム合金鍍金鋼板片を作成した。槽にアルミ用脱脂剤「NE−6」7.5%を含む水溶液を用意して60℃とし、この水溶液を脱脂用水溶液とした。又、別の槽に1.5%濃度の苛性ソーダ水溶液を40℃として用意し、これを予備塩基洗浄用の水溶液とした。又、硫酸5%含む水溶液を50℃とし、これをエッチング液とした。更に、別の槽に、中和用として25℃とした1%濃度のアンモニア水を用意した。更に別の槽に、55℃とした80%正リン酸を1.5%、亜鉛華を0.21%、珪弗化ナトリウムを0.16%、及び塩基性炭酸ニッケルを0.23%含むリン酸亜鉛型化成処理液を用意した。亜鉛アルミニウム合金鍍金鋼板片を先ず脱脂槽で5分浸漬し水洗した。次いで予備塩基洗浄槽に1分浸漬して水洗した。次いでエッチング槽に1分浸漬して水洗した。次いで中和槽に1分浸漬して水洗した。次いで化成処理層に1分浸漬して水洗した。これを90℃で15分乾燥し、表面処理を終えた。
実験例6にて表面処理した亜鉛鍍金鋼板片を取り出し、油分等が付着せぬよう手袋で摘まみ射出成形金型にインサートした。金型を閉じ調製例1により得られたPPS組成物(1)を射出温度310℃で射出した。金型温度は140℃であった。この射出接合によって、図2に示す形状の複合体20個を得た。樹脂部の大きさは10mm×45mm×5mmであり、接着面積は10mm×5mm=0.5cm2であった。成形当日に170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験した結果、平均のせん断破断力は21.8MPaであった。
調製例1により得られたPPS組成物(1)の代わりに、調製例2により得られたPPS組成物(2)を用いた以外は、実験例8と全く同様の実験を行った。即ち実験例6にて表面処理した亜鉛鍍金鋼板片を使用し、射出接合して複合体を得た。得られた複合体を170℃で1時間アニールした。要するに、ポリオレフィン系ポリマーを極僅かしか含まないPPSとフィラーのみのPPS系樹脂組成物を使用した実験である。1日後、これら10個を引っ張り試験したところ、平均のせん断破断力は7.5MPaであった。実験例8に大きく及ばず、使用した樹脂材料の差異が結果として出た。
調製例1により得られたPPS組成物(1)の代わりに、調製例3により得られたPPS組成物(3)を用いた以外は、実験例8と全く同様の実験を行った。即ち実験例6にて表面処理した亜鉛鍍金鋼板片を使用し、射出接合して複合体を得た。得られた複合体について、成形した日に170℃×1時間のアニールをし、その2日後にこの複合体に対して引っ張り試験機でせん断破断力を測定したところ、平均で20.0MPaであった。
調整例1により得られたPPS組成物(1)の代わりに、調製例4により得られたPPS組成物(4)を用いた以外は、実験例8と全く同様の実験を行った。即ち実験例6にて表面処理した亜鉛鍍金鋼板片を使用し、射出接合して複合体を得た。要するに、ポリオレフィン系ポリマーを大量に含むPPS系樹脂組成物を使用した実験である。しかしながら、成形時に多量のガスが発生し、成形を中断した。この実験では樹脂組成物の主成分がPPSではなかった。
調製例5により得られたPBT組成物(1)と、実験例6にて表面処理した亜鉛鍍金鋼板片を用いて射出接合を行った。即ち、亜鉛鍍金鋼板片を射出成形金型にインサートした。金型を閉じ調製例5により得られたPBT組成物(1)を射出温度280℃で射出した。金型温度は140℃とした。この射出接合によって、図2に示す複合体20個を得た。樹脂部の大きさは10mm×45mm×5mmであり、接着面積は10mm×5mm=0.5cm2であった。この複合体について成形当日に150℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、3個平均のせん断破断力は19.0MPaであった。
調製例5により得られたPBT組成物(1)の代わりに、ガラス繊維30%を含む市販PBT樹脂「トレコン1101G30(東レ株式会社製)」を用いた以外は、実験例12と全く同様にして射出接合を行い、複合体を得た。得られた複合体を150℃で1時間アニールした。要するに、射出接合を助力するポリマーを含まないPBTとフィラーのみのPBT系樹脂組成物を使用した実験である。1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は9.2MPaと小さく、実験例12に大きく及ばなかった。
調製例5により得られたPBT組成物(1)の代わりに、調製例6により得られたPBT組成物(2)を用いた以外は、実験例12と全く同様にして射出接合を行い、複合体を得た。得られた複合体を成形当日に150℃で1時間アニールした。その2日後にこの複合体について、引っ張り試験機を使用し、せん断破断力を測定した結果、平均で18.7MPaであった。
調製例5により得られたPBT組成物(1)の代わりに、調製例7により得られたPBT組成物(3)を用いた以外は、実験例12と全く同様にして射出接合を行い、複合体を得た。得られた複合体を成形当日に150℃で1時間アニールした。その2日後にこの複合体について、引っ張り試験機を使用し、せん断破断力を測定した結果、平均で18.1MPaであった。
実験例2にて表面処理した亜鉛鍍金鋼板片を取り出し、油分等が付着せぬよう手袋で摘まみ射出成形金型にインサートした。金型を閉じ調製例1により得られたPPS組成物(1)を射出温度310℃で射出した。金型温度は140℃とした。即ち、使用した亜鉛鍍金鋼板片が実験例6の表面処理を行った物ではなく実験例2の表面処理を行った物である以外は、実験例8と全く同様に射出接合をした。この射出接合により得られた複合体を170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は9.8MPaに過ぎず、実験例8に大きく及ばなかった。
実験例6にて表面処理した亜鉛鍍金鋼板片に代えて、実験例1にて表面処理した亜鉛鍍金鋼板片を用いる以外は、実験例8と全く同様にしてPPS組成物(1)を射出接合した。この射出接合により得られた複合体を170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は18.8MPaであった。
実験例6にて表面処理した亜鉛鍍金鋼板片に代えて、実験例3にて表面処理した亜鉛鍍金鋼板片を用いる以外は、実験例8と全く同様にしてPPS組成物(1)を射出接合した。この射出接合により得られた複合体を170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は22.5MPaであった。
実験例6にて表面処理した亜鉛鍍金鋼板片に代えて、実験例4にて表面処理した亜鉛鍍金鋼板片を用いる以外は、実験例8と全く同様にしてPPS組成物(1)を射出接合した。この射出接合により得られた複合体を170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は21.5MPaであった。
実験例6にて表面処理した亜鉛鍍金鋼板片に代えて、実験例5にて表面処理した亜鉛鍍金鋼板片を用いる以外は、実験例8と全く同様にしてPPS組成物(1)を射出接合した。この射出接合により得られた複合体を170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は19.5MPaであった。
実験例6にて表面処理した亜鉛鍍金鋼板片に代えて、実験例7にて表面処理した亜鉛アルミニウム合金鍍金鋼板片を用いる以外は、実験例8と全く同様にしてPPS組成物(1)を射出接合した。この射出接合により得られた複合体を170℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は24.8MPaであった。
実験例7にて表面処理した亜鉛アルミニウム合金鍍金鋼板片を取り出し、油分等が付着せぬよう手袋で摘まみ射出成形金型にインサートした。金型を閉じ調製例5により得られたPBT組成物(1)を射出温度280℃で射出した。金型温度は140℃とした。この射出接合によって、図2に示す複合体20個を得た。樹脂部の大きさは10mm×45mm×5mmであり、接着面積は10mm×5mm=0.5cm2であった。この複合体について成形当日に150℃の熱風乾燥機に1時間投入してアニールし、更にその1日後に引っ張り試験機を使用し、せん断破断力を測定した結果、平均のせん断破断力は23.8MPaであった。
実験例7に用いる溶融亜鉛アルミニウム合金鍍金鋼板「GL−AZ150」を18mm×45mmの長方形片に切断し、多数の亜鉛アルミニウム合金鍍金鋼板片を作成した。これら亜鉛アルミニウム合金鍍金鋼板片を65℃としたアルミ用脱脂剤「NE−6」7.5%の水溶液に7分浸漬し、水洗したものを使用する。実験例5にて表面処理した亜鉛鍍金鋼板片に代えて、この脱脂処理のみを施した亜鉛アルミニウム合金鍍金鋼板片を用いる以外は、実験例20と全く同様にしてPBT組成物(1)を射出接合した。この射出接合により得られた複合体を150℃で1時間アニールした。1日後、これらの複合体10個について引っ張り試験機を使用し、せん断破断力を測定しようと試みた。しかし、7個は引っ張り治具に付ける操作中に壊れ、残り3個の平均のせん断破断力も2.1MPaと極めて弱かった。
図3及び図4の形状の射出成形品を、1.ガラス繊維30%を含むPBT樹脂「トレコン1101G30」、2.調整例7によって得られたPBT、PET、及びポリオレフィンを主成分とするPBT組成物(3)、3.調整例1によって得られたPPS組成物(1)、4.ガラス繊維30%を含む6ナイロン樹脂「B3EG7(BASF製)」、5.ガラス繊維30%を含む芳香族ポリアミド樹脂「アミランCM3510G30(東レ株式会社製)」を使用して作成した(表1に示す5種)。得られた成形品のランナー部(ゲート部から本体に繋がる突き出し部分)を根元からニッパーでカットし、次の実験に備えた。
図5の治具システムの治具上型19の断熱材20に実験例24で作成した射出成形品22をはめこんだ。一方、実験例6に用いる0.4mm厚の溶融亜鉛鍍金鋼板を40mm×60mmに切断し、図6に示した形状の亜鉛鍍金鋼板片とした。この亜鉛鍍金鋼板片に実験例6と全く同様の表面処理をした。表面処理後の亜鉛鍍金鋼板片をホットプレートで加熱し、ピンセットで挟み掴んで図5に示した治具下型11の断熱材12の凹部にセットした。真空ポンプ26を駆動し、治具上型19と治具下型11を押し付け、2方コック28を開いた。数秒〜5秒置いたら内部は数mmHg程度になり、且つ樹脂成形品22の底部も溶融するので4方コック27を90度回転して系内を常圧に戻す。
実験例6に用いる0.4mm厚の溶融亜鉛鍍金鋼板を40mm×60mmに切断し、図6に示した形状の亜鉛鍍金鋼板片とした。この亜鉛鍍金鋼板片に実験例2と同様の表面処理をした。即ち、軽い脱脂のみを行った。表面処理後の亜鉛鍍金鋼板片を使用し、実験例25と同様の圧融着試験を行った。その結果を表1(「実験例26」)に示した。当然かもしれないが、亜鉛鍍金鋼板片と樹脂成形品は接合しないか又は接合力が極めて弱く、5種全てについて、30kgf以下で破断した。
実験例1、3、5、6にて表面処理を行った各々の亜鉛鍍金鋼板片の端部にエポキシ系接着剤「EP106(セメダイン株式会社製)」を塗り、デシケータに入れた。真空ポンプで減圧して内部圧力を3mmHgとした。この減圧状態に2分置き、常圧に戻した。この減圧/常圧戻しの操作を計3回行い、デシケータから亜鉛鍍金鋼板片を取り出した。同じ表面処理を行った亜鉛鍍金鋼板片同士を接着した形状、即ち図11に示した形状にしてクリップで固定した。接着面積は0.6〜0.7cm2になるようにした。この固定品を熱風乾燥機に入れて加熱した。即ち、100℃で1時間置き、135℃まで昇温して40分置き、その後更に昇温して165℃とし、この温度に30分保った。さらに放冷し、得られた接合体を1週間後に引っ張り試験機により破断して平均のせん断破断力を測定した。結果を表2に示した。何れも40MPa程度の非常に強い接着力を示した。
実験例2にて表面処理を行った亜鉛鍍金鋼板片を用いた以外は実験例27と全く同様の実験を行った。測定したせん断破断力を表2に示した。本実験例におけるせん断破断力は25MPaであり、実験例27の何れに対しても接着力は劣っていた。ミクロンオーダーの粗度に係る凹凸及び超微細凹凸にエポキシ系接着剤が侵入した状態で固化することで、接合力を向上せしめていることが確認された。
実験例7にて表面処理を行った亜鉛アルミニウム合金鍍金鋼板片の端部にエポキシ系接着剤「EP106」を塗り、デシケータに入れた。真空ポンプで減圧して内部圧力を3mmHgとした。この減圧状態に2分置き、常圧に戻した。この減圧/常圧戻しの操作を計3回行い、デシケータから亜鉛アルミニウム合金鍍金鋼板片を取り出した。取り出した亜鉛アルミニウム合金鍍金鋼板片同士を接着した形状、即ち図11に示した形状にしてクリップで固定した。接着面積は0.6〜0.7cm2になるようにした。この固定品を熱風乾燥機に入れて加熱した。135℃まで昇温して40分置き、その後更に昇温して165℃とし、この温度に30分保った。さらに放冷し、得られた接合体を1週間後に引っ張り試験機により破断して平均のせん断破断力を測定したところ、3対の平均で41MPaあり、非常に強い接着力を示した。
0.6mm厚の溶融亜鉛アルミニウム合金鍍金鋼板(通称ガルバリウム鋼板)「GL−AZ150」を18mm×45mmの長方形片に切断し、多数の亜鉛アルミニウム合金鍍金鋼板片を作成した。これを、実験例7で使用したのと同じ脱脂槽に5分浸漬し、よく水洗してから90℃で15分乾燥した。この脱脂処理のみ施した亜鉛アルミニウム合金鍍金鋼板片の端部にエポキシ系接着剤「EP106」を塗り、デシケータに入れた。真空ポンプで減圧して内部圧力を3mmHgとした。この減圧状態に2分置き、常圧に戻した。この減圧/常圧戻しの操作を計3回行い、デシケータから亜鉛アルミニウム合金鍍金鋼板片を取り出した。取り出した亜鉛アルミニウム合金鍍金鋼板片同士を接着した形状、即ち図11に示した形状にしてクリップで固定した。接着面積は0.6〜0.7cm2になるようにした。この固定品を熱風乾燥機に入れて加熱した。135℃まで昇温して40分置き、その後更に昇温して165℃とし、この温度に30分保った。さらに放冷し、得られた接合体を1週間後に引っ張り試験機により破断して平均のせん断破断力を測定したところ、3対の平均で28MPaあり強い接着力を示したが、実験例29には大きく及ばなかった。ミクロンオーダーの粗度に係る凹凸及び超微細凹凸にエポキシ系接着剤が侵入した状態で固化することで、接合力を向上せしめていることが確認された。
CFRPプリプレグを作成するために表3からなる熱硬化性樹脂を作成した。
実験例6にて表面処理を行った亜鉛鍍金鋼板片の端部に実験例27と同じエポキシ系接着剤「EP106」を塗布し、更にデシケータに入れて減圧/常圧戻しの操作を3回加えた。前述した図9に示す焼成治具41を用いて亜鉛鍍金鋼板片とCFRP片との複合体を作成する。即ち、図9において減圧/常圧戻しの操作を3回加えた亜鉛系鍍金鋼板片51の端部の上に、別途切断しておいた炭素繊維「T−300」を敷く。この「T−300」に、注射器から出すエポキシ系接着剤「EP−106」を塗り、その上に2段目の「T−300」を敷き、これにも同じ接着剤を塗り、さらにその上に3段目の「T−300」を敷き、これにも同じ接着剤を塗る。このようにしてエポキシ系接着剤が染み込んだ炭素繊維3枚が層状に重なった状態(図9では52として示される)とした。使用した接着剤「EP−106」は約1ccであった。
実験例6にて表面処理を行った亜鉛鍍金鋼板片の端部に実験例27と同じエポキシ系接着剤「EP106」を塗布し、更にデシケータに入れて減圧/常圧戻しの操作を3回加えた。前述した図9に示す焼成治具41を用いて亜鉛鍍金鋼板片とCFRP片(実験例31で作成したCFRPプリプレグの硬化物)との複合体を作成する。即ち、図9において減圧/常圧戻しの操作を3回加えた亜鉛系鍍金鋼板片51の端部の上に、実験例31で作成したCFRPプリプレグを3枚積層する(図9では52として示される)。
GFRP用の市販のビニルエステル型不飽和ポリエステル「リポキシR802(昭和高分子株式会社製)」10gとt−ブチルパーオキシベンゾエート「パーブチルZ(日油株式会社製)」0.1gをよく混ぜて接着剤とした。実験例6にて表面処理を行った亜鉛鍍金鋼板片の端部にこの接着剤を塗り、デシケータに入れた。真空ポンプで減圧して内部圧力を50mmHg以下とした。この減圧状態になったら数秒置いて常圧に戻した。この減圧/常圧戻しの操作を計3回行い、デシケータから亜鉛鍍金鋼板片を取り出した。取り出した亜鉛鍍金鋼板片同士を接着した形状、即ち図11に示した形状にしてクリップで固定し、これを3組作った。接着面積は0.6〜0.7cm2になるようにした。この固定品を熱風乾燥機に入れて加熱した。90℃まで昇温して1時間置き、その後更に昇温して120℃とし、この温度に1時間保った。さらに放冷し、得られた接合体を1週間後に引っ張り試験機により破断して平均のせん断破断力を測定したところ、27MPaであり、非常に強かった。
Claims (22)
- 亜鉛系鍍金鋼板と被着材の接合体であって、
前記亜鉛系鍍金鋼板の表面は、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を有し、且つ、その粗度を有する面内には10〜300nm周期の超微細凹凸が形成され、且つ、表層が金属酸化物又は金属リン酸化物の薄層であり、
前記被着材は、ポリブチレンテレフタレート、ポリフェニレンサルファイド、及び芳香族ポリアミドから選択される1種以上を主成分とする熱可塑性樹脂組成物の樹脂成形品であり、
前記亜鉛系鍍金鋼板と前記樹脂成形品は、前記超微細凹凸に侵入して硬化した前記熱可塑性樹脂組成物を介して接合されていることを特徴とする前記接合体。 - 請求項1に記載した亜鉛系鍍金鋼板と被着材の接合体であって、
前記熱可塑性樹脂組成物は、ポリブチレンテレフタレートを70ないし97質量%、ポリエチレンテレフタレート及び/又はポリオレフィン系樹脂を3ないし30質量%含むことを特徴とする前記接合体。 - 請求項1に記載した亜鉛系鍍金鋼板と被着材の接合体であって、
前記熱可塑性樹脂組成物は、ポリフェニレンサルファイドを70ないし97質量%、ポリオレフィン系樹脂を3ないし30質量%含むことを特徴とする前記接合体。 - 請求項1に記載した亜鉛系鍍金鋼板と被着材の接合体であって、
前記熱可塑性樹脂組成物は、芳香族ポリアミドを50ないし100質量%、脂肪族ポリアミドを0ないし50質量%含むことを特徴とする前記接合体。 - 請求項2又は3に記載した亜鉛系鍍金鋼板と被着材の接合体であって、
前記熱可塑性樹脂組成物は、ガラス繊維、炭素繊維、アラミド繊維、炭酸カルシウム、炭酸マグネシウム、シリカ、タルク、粘土、及びガラス粉から選択される1種以上の充填材を、20〜60質量%含むことにより、前記樹脂成形品の線膨張率を2.0×10−5℃−1〜3.0×10−5℃−1の範囲としたことを特徴とする前記接合体。 - 亜鉛系鍍金鋼板と被着材の接合体であって、
前記亜鉛系鍍金鋼板の表面は、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を有し、且つ、その粗度を有する面内には10〜300nm周期の超微細凹凸が形成され、且つ、表層が金属酸化物又は金属リン酸化物の薄層であり、
前記被着材は、ポリブチレンテレフタレート、ポリフェニレンサルファイド、芳香族ポリアミド、脂肪族ポリアミド、及び液晶ポリマーから選択される1種以上を主成分とする硬質の高結晶性樹脂の樹脂成形品であり、
前記亜鉛系鍍金鋼板と前記樹脂成形品は、前記超微細凹凸に侵入して硬化した前記高結晶性樹脂を介して接合されていることを特徴とする前記接合体。 - 亜鉛系鍍金鋼板と被着材の接合体であって、
前記亜鉛系鍍金鋼板の表面は、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を有し、且つ、その粗度を有する面内には10〜300nm周期の超微細凹凸が形成され、且つ、表層が金属酸化物又は金属リン酸化物の薄層であり、
前記被着材はフェノール樹脂をマトリックスとする摩擦材又は研磨材であり、
前記亜鉛系鍍金鋼板と前記摩擦材又は研磨材は、前記超微細凹凸に侵入して硬化したフェノール系接着剤を介して接合されていることを特徴とする前記接合体。 - 亜鉛系鍍金鋼板と被着材の接合体であって、
前記亜鉛系鍍金鋼板の表面は、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を有し、且つ、その粗度を有する面内には10〜300nm周期の超微細凹凸が形成され、且つ、表層が金属酸化物又は金属リン酸化物の薄層であり、
前記被着材はエポキシ樹脂をマトリックスとする炭素繊維強化プラスチックであり、
前記亜鉛系鍍金鋼板と前記炭素繊維強化プラスチックは、前記超微細凹凸に侵入して硬化したエポキシ系接着剤を介して接合されていることを特徴とする前記接合体。 - 亜鉛系鍍金鋼板と被着材の接合体であって、
前記亜鉛系鍍金鋼板の表面は、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を有し、且つ、その粗度を有する面内には10〜300nm周期の超微細凹凸が形成され、且つ、表層が金属酸化物又は金属リン酸化物の薄層であり、
前記被着材は不飽和ポリエステル樹脂をマトリックスとするガラス繊維強化プラスチックであり、
前記亜鉛系鍍金鋼板と前記ガラス繊維強化プラスチックは、前記超微細凹凸に侵入して硬化した不飽和ポリエステル系接着剤を介して接合されていることを特徴とする前記接合体。 - 亜鉛系鍍金鋼板と被着材の接合体であって、
前記被着材は金属合金であり、
前記亜鉛系鍍金鋼板及び前記金属合金の双方の表面は、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を有し、且つ、その粗度を有する面内には10〜300nm周期の超微細凹凸が形成され、且つ、表層が金属酸化物又は金属リン酸化物の薄層であり、
前記亜鉛系鍍金鋼板と前記金属合金の双方の超微細凹凸には、(1)エポキシ系接着剤、(2)フェノール系接着剤、及び(3)不飽和ポリエステル系接着剤の(1)〜(3)から選択される1種の熱硬化型接着剤が侵入した状態で硬化し、その硬化した熱硬化型接着剤を介して当該亜鉛系鍍金鋼板と当該金属合金が強固に接合されていることを特徴とする前記接合体。 - 請求項1、及び7ないし10から選択される1項に記載した亜鉛系鍍金鋼板と被着材の接合体であって、
前記亜鉛系鍍金鋼板は亜鉛アルミニウム合金鍍金鋼板であることを特徴とする前記接合体。 - 亜鉛系鍍金鋼板の表面に、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を生じさせ、且つ、その粗度を有する面内に、10〜300nm周期の超微細凹凸を形成し、且つ、表層を金属酸化物又は金属リン酸化物の薄層とするための液処理を行う表面処理工程と、
前記表面処理工程を経た亜鉛系鍍金鋼板を射出成形金型にインサートするインサート工程と、
インサートされた前記亜鉛系鍍金鋼板の表面に、ポリブチレンテレフタレート、ポリフェニレンサルファイド、及び芳香族ポリアミドから選択される1種以上を主成分とする熱可塑性樹脂組成物を射出し、当該射出された熱可塑性樹脂組成物が前記超微細凹凸に侵入した後に硬化することによって前記亜鉛系鍍金鋼板と当該熱可塑性樹脂組成物の成形品が強固に一体化される一体化工程と、
を含むことを特徴とする亜鉛系鍍金鋼板と被着材の接合体の製造方法。 - 亜鉛系鍍金鋼板の表面に、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を生じさせ、且つ、その粗度を有する面内に、10〜300nm周期の超微細凹凸を形成し、且つ、表層を金属酸化物又は金属リン酸化物の薄層とするための液処理を行う表面処理工程と、
ポリブチレンテレフタレート、ポリフェニレンサルファイド、芳香族ポリアミド、脂肪族ポリアミド、及び液晶ポリマーから選択される1種以上を主成分とする樹脂組成物の樹脂成形品を作成する樹脂成形品作成工程と、
前記表面処理工程を経た亜鉛系鍍金鋼板の表面を、前記樹脂組成物の溶融温度以上の温度に加熱する加熱工程と、
前記加熱工程を経た亜鉛系鍍金鋼板の表面に前記樹脂成形品を押し付けて、その樹脂組成物を溶融させた状態とし、当該亜鉛系鍍金鋼板及び樹脂成形品を減圧下に置き、その後に加圧することにより、その溶融した樹脂組成物を前記超微細凹凸に侵入させ、その侵入した樹脂が硬化することにより当該該亜鉛系鍍金鋼板及び樹脂成形品を融着させる圧融着工程と、
を含むことを特徴とする亜鉛系鍍金鋼板と被着材の接合体の製造方法。 - 亜鉛系鍍金鋼板の表面に、山谷平均間隔(RSm)が0.8〜10μm、最大高さ粗さ(Rz)が0.2〜5μmであるミクロンオーダーの粗度を生じさせ、且つ、その粗度を有する面内に、10〜300nm周期の超微細凹凸を形成し、且つ、表層を金属酸化物又は金属リン酸化物の薄層とするための液処理を行う表面処理工程と、
前記表面処理工程を経た亜鉛系鍍金鋼板の表面に(1)エポキシ系接着剤、(2)フェノール系接着剤、及び(3)不飽和ポリエステル系接着剤の(1)〜(3)から選択される1種の熱硬化型接着剤を塗布する塗布工程と、
前記塗布工程を経た亜鉛系鍍金鋼板を密閉容器に収納して減圧し、その後に加圧することにより、塗布した熱硬化型接着剤を前記超微細凹凸に侵入させる接着予備工程と、
前記接着予備工程を経た亜鉛系鍍金鋼板の表面に被着材を密着させて固定する固定工程と、
前記固定された亜鉛系鍍金鋼板及び被着材を加熱して接着剤成分を硬化させる硬化工程と、
を含むことを特徴とする亜鉛系鍍金鋼板と被着材の接合体の製造方法。 - 請求項14に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記熱硬化型接着剤はエポキシ系接着剤であって、
前記被着材はエポキシ樹脂をマトリックスとする炭素繊維強化プラスチックであることを特徴とする前記製造方法。 - 請求項14に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記熱硬化型接着剤は、エポキシ系接着剤又は不飽和ポリエステル系接着剤であって、
前記被着材も、前記表面処理工程、前記塗布工程、及び前記接着予備工程を経た亜鉛系鍍金鋼板であることを特徴とする前記製造方法。 - 請求項12又は14に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記表面処理工程において実施される液処理は、亜鉛系鍍金鋼板をアルミニウム用脱脂溶液に浸漬する脱脂処理のみであることを特徴とする前記製造方法。 - 請求項17に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記亜鉛系鍍金鋼板は、JIS G3302に規定されるZ18であり、
前記脱脂処理において、Z18を70℃以上としたアルミニウム用脱脂溶液に5〜10分浸漬することを特徴とする前記製造方法。 - 請求項12ないし14から選択される1項に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記表面処理工程において実施される液処理は、亜鉛系鍍金鋼板をアルミニウム用脱脂溶液に浸漬する脱脂処理、並びに3価クロム、6価クロム、リン酸、及びニッケルを含む水溶液に浸漬するクロメート処理であることを特徴とする前記製造方法。 - 請求項12又は14に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記表面処理工程において実施される液処理は、亜鉛系鍍金鋼板をアルミニウム用脱脂溶液に浸漬する脱脂処理、並びにリン酸、2価亜鉛、ニッケル、及び珪弗化物を含む水溶液に浸漬するリン酸亜鉛型処理であることを特徴とする前記製造方法。 - 請求項12又は14に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記表面処理工程において実施される液処理は、亜鉛系鍍金鋼板をアルミニウム用脱脂溶液に浸漬する脱脂処理、並びにリン酸、2価亜鉛、カルシウム、及びニッケルを含む水溶液に浸漬するリン酸亜鉛カルシウム型処理であることを特徴とする前記製造方法。 - 請求項12又は14に記載した亜鉛系鍍金鋼板と被着材の接合体の製造方法であって、
前記亜鉛系鍍金鋼板は亜鉛アルミニウム合金鍍金鋼板であって、
前記表面処理工程において実施される液処理は、亜鉛アルミニウム合金鍍金鋼板をアルミニウム用脱脂溶液に浸漬する脱脂処理、pH1〜3の酸性水溶液に浸漬する化学エッチング、並びに(1)3価クロム、6価クロム、リン酸、及びニッケルを含む水溶液に浸漬するクロメート処理(2)リン酸、2価亜鉛、ニッケル、及び珪弗化物を含む水溶液に浸漬するリン酸亜鉛型処理、及び(3)リン酸、2価亜鉛、カルシウム、及びニッケルを含む水溶液に浸漬するリン酸亜鉛カルシウム型処理の(1)〜(3)から選択される1種の化成処理を含むことを特徴とする前記製造方法。
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JP2006027018A (ja) * | 2004-07-14 | 2006-02-02 | Taisei Plas Co Ltd | 金属と樹脂の複合体およびその製造方法 |
JP2008038188A (ja) * | 2006-08-03 | 2008-02-21 | Nippon Steel Corp | 薄膜一次防錆被覆層を有する表面導電性に優れた亜鉛系めっき鋼板とその製造方法 |
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US20140305903A1 (en) | 2014-10-16 |
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US20110008644A1 (en) | 2011-01-13 |
US9567675B2 (en) | 2017-02-14 |
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