TW201446463A - Composite molded-body production method - Google Patents

Abstract

Provided is a composite molded-body production method by which adhesive strength can be improved. The composite molded-body production method for a composite molded-body in which a metal molded body and a resin molded body are adhered together is a process in which an adhesion surface of the metal molded body is irradiated by a laser beam having a laser spot diameter of 10-200[mu]m to form a groove, and either a ring having a diameter of 20-1000[mu]m, or a region having a similar surface-area range, is formed. The composite molded-body production method includes: a first step in which a first scan forms a groove such that the laser-irradiation start point and end point are linked, and a plurality of repeated scans forms a region that is enclosed by the groove; a second step in which the first step is repeated to form a plurality of regions enclosed by grooves; and a third step in which a molded-body section that includes the adhesion surface on which the regions enclosed by grooves are formed is positioned inside a metal mold and the resin that becomes the resin molded body is subjected to insert molding.

Description

Method for manufacturing composite formed body

The present invention relates to a method of producing a composite molded body comprising a metal formed body and a resin molded body.

From the viewpoint of weight reduction of various parts, a resin molded body is used as a metal substitute, but it is difficult to replace all metal parts with a resin. In this case, it is considered to manufacture a new composite part by joining the metal formed body and the resin molded body into one body.

However, a technique in which a metal formed body and a resin molded body are integrally joined by an industrially advantageous method and with high joint strength has not been put to practical use.

Japanese Patent No. 4020957 describes an invention of a laser processing method for a metal surface joined to a different material (resin), comprising: a step of performing laser scanning on a metal surface in a scanning direction; The step of performing a laser scan in the scanning direction of the intersection.

Japanese Laid-Open Patent Publication No. 2010-167475 discloses an invention of a laser processing method in which laser scanning is performed plural times in a superimposed manner in the invention of Japanese Patent No. 4020957.

However, the invention of Japanese Patent No. 4020957 and Japanese Patent Laid-Open No. 2010-167475 requires laser scanning in both directions of intersection, and therefore there is room for improvement in terms of excessively long processing time.

Further, it is considered that since the surface roughening treatment can be performed by laser scanning in the intersecting direction, the joint strength can be improved, but there are problems in that the surface roughness state is uneven, and the strength of the joint portion of the metal and the resin is present. The directional instability is ambiguous.

For example, there is a joining body having the highest shearing force or tensile strength in the X-axis direction, but the other joining body has the highest shearing force or tensile strength in the Y-axis direction different from the X-axis direction. Further, the other joined body has a problem that the shearing force or the tensile strength in the Z-axis direction which is different from the X-axis and the Y-axis direction is the highest.

In the case of a product (for example, a rotating body part in one direction or a reciprocating part in one direction), there is a case where a composite of metal and resin having a high joint strength in a specific direction is required, but Japanese Patent No. 4020957, Japanese Special The invention of the publication No. 2010-167475 does not fully comply with the aforementioned requirements.

Further, in the case where the joint surface has a complicated shape or a shape including a portion having a narrow width (for example, a star shape, a triangle shape, or a dumbbell shape), it is considered that a method of performing laser scanning in the cross direction causes a roughening of the surface portion. It becomes uneven, and as a result, sufficient joint strength cannot be obtained.

Japanese Laid-Open Patent Publication No. Hei 10-294024 discloses a method of manufacturing an electric and electronic component in which a metal surface is irradiated with laser light to form irregularities, and a molded resin, rubber, or the like is injected to the uneven portion.

In the first to third embodiments, the surface of the metal long coil is subjected to laser irradiation to form irregularities. Further, as described in paragraph No. 10, the surface of the metal long-sized coil is roughened into a strip shape or a satin shape; as described in paragraph No. 19, the surface of the metal long-length coil is roughened into a strip shape, a dotted line shape, a wavy line shape, and a rolling pattern. Shaped, satin-like.

However, as described in the effects of the inventions of paragraphs Nos. 21 and 22, the purpose of performing laser irradiation is to improve the registration effect by forming fine and irregular irregularities on the metal surface. In particular, since the object to be processed is a metal long-sized coil, it is considered that fine irregularities are inevitably formed regardless of the unevenness formed.

In the invention of Japanese Laid-Open Patent Publication No. 2010-167475, the laser beam is irradiated in the intersecting direction to form fine irregularities on the surface. Invent the same technical idea.

International Publication No. 2012/090671 is an invention of a method for producing a composite molded body comprising a metal molded body and a resin molded body. The step of performing laser scanning in such a manner as to form a joint surface of the metal formed body to form marks including straight lines and/or curves in one direction or different directions, and to mark each line and/or each curve with each other The step of performing a laser scan without crossing. Fig. 6 to Fig. 9 show a square, circular, elliptical, triangular mark pattern.

The present invention has been made in an effort to provide a method for producing a composite molded article which can further improve the joint strength.

As a solution to the problem, the present invention provides a method for producing a composite molded body, which is a method for producing a composite molded body obtained by joining a metal molded body and a resin molded body, comprising: a first step of the metal The joint surface of the molded body is irradiated with laser light having a laser spot diameter of 10 to 200 μm to form a groove, and the diameter is formed. a step of a circle of 20 to 1000 μm or a region of the same area, forming a groove by connecting the start point and the end point of the laser irradiation with one scan, and repeating the plurality of scans to form a groove surrounded by the groove a second step of repeating the first step to form a plurality of regions surrounded by the grooves; and a third step of disposing a portion including the joined surface of the metal molded body in which the regions surrounded by the grooves are formed in the mold Inside, the resin is molded into the resin molded body.

According to the method for producing a composite molded article of the present invention, the joint strength between the metal molded body and the resin molded body can be improved.

1‧‧‧Composite shaped body

10‧‧‧Metal forming body

12‧‧‧ joint surface

20‧‧‧Resin molded body

Fig. 1 is a cross-sectional view (including a partial enlarged view) in the thickness direction of the composite molded body obtained by the production method of the present invention.

Fig. 2 is a cross-sectional view in the radial direction of a composite molded body according to another embodiment of the present invention, wherein (a) is a side view and (b) is an end view.

Fig. 3 is an explanatory view showing a manufacturing method of the present invention, which is a plan view (right side) and a partial enlarged view (left side) thereof.

Fig. 4 (a) to (g) are views showing a pattern of formation of a region surrounded by a structure in the manufacturing method of the present invention.

Fig. 5 is an explanatory view of a manufacturing method in the embodiment.

Fig. 6(a) is a SEM photograph of a plan view of a metal formed body used in the composite molded body of Example 1, and Fig. 6(b) is an enlarged view of Fig. 6(a); c) is a SEM photograph of the cross section in the thickness direction of Fig. 6(a).

Fig. 7 is an explanatory view showing a manufacturing method of Comparative Example 1.

Fig. 8 is a view for explaining a method of measuring the joint strength of the composite molded articles of the examples and the comparative examples.

[Formation of the Invention]

1 is a cross-sectional view (including a partial enlarged view) of the composite molded body 1 in which the metal formed body 10 of the flat plate and the resin molded body 20 of the flat plate are joined to each other in a plane.

Fig. 2(a) is a cross-sectional view showing the thickness (diameter) direction of the composite molded body 1 in which the metal formed body 10 of the column (round bar) and the resin molded body 20 of the column are joined together by a curved surface.

The composite molded body 1 of Figs. 1 and 2 can be produced through the following first step, second step, and third step.

<Step 1>

As shown in the plan view and the partial enlarged view of Fig. 3, in the first step, the bonding surface of the metal formed body 10 before joining and joining is irradiated with a laser spot diameter (d) of 10 to 200 μm. The light is formed by the laser beam 31 to form a circular shape having a diameter (D) of 20 to 1000 μm or a region of the same area.

Further, in the first step, the groove 31 is formed by connecting the start point and the end point of the laser irradiation by one scan, and the plurality of scans are repeated so that the same groove 31 is formed, thereby forming the groove 31. An area surrounded by.

The diameter D of a region (circular region) 30 formed by the groove 31 and the convex portion 32 serves as the diameter of the contact circle outside the laser spot.

The groove 31 is formed by connecting the start point and the end point of the laser irradiation by one scan as shown in a partially enlarged view of FIG. That is, the laser irradiation is performed such that the laser spots adjacent in the circumferential direction are repeated or in contact with each other.

Then, in the second scan, a plurality of scans are performed on the same groove 31 as in the first scan. The depth of the groove 31 (i.e., the height of the convex portion 32) is adjusted by performing a plurality of scans.

In the first step, the region 30 surrounded by the groove 31 may be selected from the pentagon or more in addition to the circular, elliptical, triangular, and quadrilateral shapes as shown in Figs. 4(a) to (g). The polygonal shape and the desired irregular shape may also be areas including other shapes.

When it is regarded as a region other than a circle, it is formed into a circle having a diameter (D) of 20 to 1000 μm or a region of the same area.

The laser spot diameter (d) is 10 to 200 μm, preferably 10 to 100 μm, more preferably 10 to 50 μm.

The size of a region is a circle having a diameter (D) of 20 to 1000 μm or a region of the same area, preferably a circle having a diameter (D) of 20 to 500 μm or a region of the same area, more preferably a diameter (D). It is a circle of 20~300μm or the same area range.

The irradiation distance of one scan is preferably from 100 to 100,000 μm, more preferably from 100 to 10,000 μm, still more preferably from 100 to 1000 μm. By shortening the irradiation distance of one scan in this way, it is possible to suppress the diffusion of heat between scans and the decrease in the temperature of the metal. Therefore, the efficiency of laser processing (processing amount per unit time) becomes good.

The groove depth formed by laser irradiation with one scan is preferably 5 to 300 μm, more preferably 10 to 300 μm.

The groove depth after all scanning is preferably from 10 to 600 μm, more preferably from 10 to 300 μm.

The irradiation conditions of the laser light when the region 30 including the groove is formed are as follows: the output power is preferably 4 to 4000 W.

The wavelength is preferably from 300 to 1200 nm, more preferably from 500 to 1200 nm.

The pulse width of one scan (the irradiation time of the laser light for one scan) is preferably from 1 to 10,000 nsec.

The frequency is preferably from 1 to 100 kHz.

The focus position is preferably -10 to +10 mm, more preferably -6 to +6 mm.

The processing speed is preferably from 10 to 10,000 mm/sec, more preferably from 100 to 10,000 mm/sec, still more preferably from 300 to 10,000 mm/sec.

The number of scans is preferably 1 to 30 times.

<Step 2>

In the second step, the first step is repeated, and a plurality of regions 30 (30a to 30g) shown in Figs. 4(a) to 4(g) are formed on the joint surface 12 of the metal formed body 10.

In Figs. 4(a) to 4(e), a region 30 (30a to 30e) is formed on the entire surface of the joint surface 12; and Figs. 4(f) and (g) are formed on a portion of the joint surface 12. 30 (30f, 30g).

In Fig. 4(a), a plurality of circular regions 30a having grooves 31a and convex portions 32a are formed at equal intervals. The plurality of circular regions 30a are each independently and not in contact, but the grooves 31a of all or a portion of the regions 30a may be overlapped with each other.

In Fig. 4(b), a plurality of elliptical regions 30b having grooves 31b and convex portions 32b are formed at equal intervals. The plurality of elliptical regions 30a are each independently and not in contact, but the grooves 31b of all or a portion of the regions 30b may be overlapped with each other.

In Fig. 4(c), a plurality of triangular regions 30c having grooves 31c and convex portions 32c are formed at equal intervals. The plurality of triangular regions 30c are each independently and not in contact, but the grooves 31c of all or a portion of the regions 30c may be overlapped with each other.

In Fig. 4(d), a plurality of quadrangular regions 30d having grooves 31d and convex portions 32d are formed at equal intervals. The plurality of quadrangular regions 30d are each independently and not in contact, but the grooves 31d of all or a portion of the regions 30d may be overlapped with each other.

In Fig. 4(e), in a state different from that of Fig. 4(a), a plurality of circular regions 30e having grooves 31e and convex portions 32e are formed at equal intervals. The plurality of circular regions 30e are each independently and not in contact, but the grooves 31e of all or a portion of the regions 30e may be overlapped with each other.

In Fig. 4(f), different from Fig. 4(a) and Fig. 4(e), a plurality of circular regions 30f having grooves 31f and convex portions 32f are formed on a part of the surface of the joint surface 12. The plurality of circular regions 30f are independent and not in contact with each other, but the grooves 31f of all or a portion of the regions 30f may be overlapped with each other.

In Fig. 4(f), the plurality of circular regions 30f are formed such that the formation density of the circular portion 30f on the side of the side 12a of the joint surface 12 is increased, and the circular portion 30f on the side of the opposite side 12b is formed. The formation density is formed in a manner that becomes lower. As described above, the circular regions 30f are not uniformly disposed on the joint surface 12, and may be formed to be biased to exist on a part of the surface.

When the composite molded body 1 shown in Fig. 1 is formed with a plurality of circular regions 30f shown in Fig. 4(f) on the joint surface 12, the circular region 30f is formed densely on the side of the side 12a. According to the configuration, the composite molded body 1 has a large resistance when stretched in the direction of the arrow in the fourth diagram (f), and the joint strength between the metal molded body 10 and the resin molded body 20 can be improved.

In Fig. 4(g), a plurality of circular regions 30g having grooves 31g and convex portions 32g are formed around the joint surface 12, unlike the fourth drawings (a) and (e), and are not formed at the center portion. A circular area 30g. The plurality of circular regions 30g are independent and not in contact with each other, but the grooves 31g of all or a part of the regions 30g may be overlapped with each other.

Further, contrary to Fig. 4(g), a plurality of circular regions 30g may be formed only in the central portion of the joint surface 12, and the circular region 30g may not be formed around.

<Step 3>

In the third step, a portion including the joint surface 12 of the metal formed body 10 in which the plurality of regions 30 are formed is placed in a mold, and the resin molded into the resin molded body 20 is insert-molded to obtain a composite molded body 1.

By the insert molding step, as shown in Fig. 1, the composite molded body 1 in which the resin is infiltrated into the groove 31 of the region 30 (the groove 31 and the projection 32).

As described above, since the metal formed body 10 has the region 30 (the groove 31 and the projection 32), the contact area between the metal formed body 10 and the resin molded body 20 can be increased, and the alignment generated by filling the groove 31 with the resin can be achieved. The effect is to increase the joint strength.

Further, for example, as shown in Fig. 4 (a) to (g), by adjusting the arrangement state of the region 30 or adjusting the pattern formation, it is possible to obtain a composite shape in which the tensile strength or the bending strength in the desired direction is improved. body.

The metal of the metal formed body used in the composite molded article of the present invention is not particularly limited, and may be appropriately selected from known metals depending on the application. For example, those selected from the group consisting of iron, various stainless steels, aluminum or alloys thereof, copper or alloys thereof, silver or alloys thereof, zinc, magnesium, lead, tin, and alloys containing the same may be mentioned.

The method for forming the metal formed body used in the composite molded article of the present invention is not particularly limited, and it can be produced by various known molding methods depending on the type of metal, and can be produced, for example, by a die casting method.

The resin of the resin molded body used in the composite molded article of the present invention contains a thermoplastic elastomer in addition to the thermoplastic resin and the thermosetting resin.

The thermoplastic resin can be appropriately selected from known thermoplastic resins depending on the use. Examples thereof include a polyamide-based resin (aliphatic polyamines such as PA6 and PA66, and an aromatic polyamine), a copolymer containing styrene units such as polystyrene, ABS resin, and AS resin, and a polyethylene-containing unit. Copolymer, polypropylene, copolymer containing propylene unit, other polyolefin, polyvinyl chloride, polyvinylidene chloride, polycarbonate resin, acrylic resin, methacrylic resin, polyester resin, Polyacetal resin or polyphenylene sulfide resin.

The thermosetting resin can be appropriately selected from known thermosetting resins depending on the application. For example, a urea resin, a melamine resin, a phenol resin, a resorcin resin, an epoxy resin, a polyurethane, and a vinyl urethane are mentioned.

The thermoplastic elastomer can be appropriately selected from known thermoplastic elastomers depending on the use. For example, a styrene-based elastomer, a vinyl chloride-based elastomer, an olefin-based elastomer, an urethane-based elastomer, a polyester-based elastomer, a nitrile-based elastomer, and a polyamine-based elastomer can be mentioned.

A well-known fibrous filler can be blended in these thermoplastic resins, thermosetting resins, and thermoplastic elastomers.

As a well-known fibrous filler, carbon fiber, inorganic fiber, metal fiber, organic weaving, etc. are mentioned.

Carbon fibers are well known, and fibers such as PAN, asphalt, lanthanum, and wood are used.

Examples of the inorganic fibers include glass fibers, basalt fibers, cerium oxide fibers, cerium oxide ‧ alumina fibers, zirconia fibers, boron nitride fibers, and tantalum nitride fibers.

Examples of the metal fiber include fibers including stainless steel, aluminum, copper, and the like.

As the organic fiber, a polyamide fiber (a wholly aromatic polyamide fiber, a semi-aromatic polyamide fiber in which an aromatic compound is a diamine or a dicarboxylic acid, or an aliphatic polyamide fiber) can be used. Polyvinyl alcohol fiber, acrylic fiber, polyolefin fiber, polyoxymethylene fiber, polytetrafluoroethylene fiber, polyester fiber (including wholly aromatic polyester fiber), polyphenylene sulfide fiber, polyimine fiber, liquid crystal polyester fiber Such as synthetic fibers or natural fibers (cellulosic fibers, etc.) or regenerated cellulose (嫘萦) fibers.

For the fibrous filler, a fiber diameter of 3 to 60 μm can be used. However, among these, it is preferable to use, for example, a fiber pattern having a smaller fiber diameter than the joint surface 11 of the metal molded body 10. The width (the size of the opening of the pore or the groove width). The fiber diameter is more preferably 5 to 30 μm, and still more preferably 7 to 20 μm.

When such a fibrous filler having a fiber diameter smaller than the width of the marking pattern is used, a composite molded body in which a part of the fibrous filler is adhered to the marking pattern of the metal molded body can be obtained, and the metal formed body and the resin can be formed. The bonding strength of the body is therefore preferred.

In addition, since the fibrous filler is formed by increasing the mechanical strength of the resin molded body and reducing the mechanical strength difference from the metal molded body to improve the joint strength between the metal molded body and the resin molded body, it is preferable to form the fibrous filler. The weight average fiber length contained in the subsequent resin molded body can be preferably from 0.1 to 5.0 mm, more preferably from 0.1 to 4.0 mm, still more preferably from 0.2 to 3.0 mm, most preferably from 0.5 to 2.5 mm. Used as a raw material for manufacturing.

The blending amount of the fibrous filler of the thermoplastic resin, the thermosetting resin, and the thermoplastic elastomer is preferably from 5 to 250 parts by mass per 100 parts by mass. More preferably, it is 25 to 200 parts by mass, and further more preferably 45 to 150 parts by mass.

A well-known laser can be used in the method for producing a composite formed article of the present invention, and for example, a YVO ₄ laser, a YAG laser, a fiber laser, an excimer laser, an ultraviolet laser, a carbon dioxide laser, a semiconductor laser, or the like can be used. Glass laser, ruby laser, He-Ne laser, nitrogen laser, chelate laser, pigment laser.

The irradiation conditions of the laser, for example, the wavelength, the beam diameter, the interval between the pores, the number of the waves, and the like, may be appropriately determined depending on the size, quality, type, or even the required joint strength of the metal molded body and the resin molded body to be bonded. Decide.

[Examples] Example 1

The joint surface 12 of the metal molded body (aluminum: A5052) shown in Fig. 5 was subjected to laser irradiation under the conditions shown in Table 1, and 372 circular regions 30a shown in Fig. 4(a) were formed. Further, the laser oscillator is a fiber laser (YLP-1-50-30-30RA manufactured by IPG).

Fig. 6(a) is a SEM photograph (100 times) of a plan view of the metal formed body used in Example 1, and Fig. 6(b) is an enlarged photograph (200 times) of (a); Fig. 6(c) SEM photograph (100 times) of the cross section in the thickness direction of Fig. 6(a).

After forming a circular region in the metal formed body in the above manner, insert molding was carried out in the following manner to obtain a composite molded article of Example 1.

Comparative example 1

The joint surface 12 of the metal molded body (aluminum: A5052) shown in Fig. 5 was subjected to laser irradiation under the conditions shown in Table 1, and a groove including a straight line bent a plurality of times as shown in Fig. 7 was formed. Further, the laser oscillator is a fiber laser (YLP-1-50-30-30RA manufactured by IPG).

After forming a groove including a straight line in the metal formed body in the above manner, insert molding was carried out in the following manner to obtain a composite molded body of Comparative Example 1.

Comparative example 2

The joint surface 12 of the metal molded body (aluminum: A5052) shown in Fig. 5 was subjected to laser irradiation under the conditions shown in Table 1, and a groove including a straight line bent a plurality of times as shown in Fig. 7 was formed. Further, the laser oscillator is a fiber laser (YLP-1-50-30-30RA manufactured by IPG).

After forming a groove including a straight line in the metal formed body in the above manner, insert molding was carried out in the following manner to obtain a composite molded body of Comparative Example 2.

<Insert forming (injection forming)>

Resin: GF60% reinforced PA66 resin (Plastron PA66-GF60-01 (L7): Daicel Polymer (manufactured by Daicel Polymer)), fiber length of glass fiber: 11mm

Resin temperature: 320 ° C

Mold temperature: 100 ° C

Injection molding machine: ROBOSHOT S2000i-100B made by FANUC

[Stretching test]

Using the composite molded articles of Example 1 and Comparative Examples 1 and 2, a tensile test was conducted and the joint strength (S1) was evaluated. The results are shown in Table 1.

Further, the fiber length (weight average fiber length) of the glass fibers in the resin molded body of the composite molded body was 0.85 mm. The average fiber length was cut out from the molded product by about 3 g of the sample, heated at 650 ° C, ashed, and the glass fiber was taken out. The weight average fiber length was determined from a part (500 pieces) of the taken-out fiber. The calculation formula is [0044] and [0045] of JP-A-2006-274061.

In the tensile test, the maximum load when the metal molded body and the resin molded body were broken in the X1 direction shown in Fig. 8 was measured while being fixed to the metal molded body side.

<Tensile test conditions>

Testing machine: Tensilon (UCT-1T) manufactured by Orientec

Stretching speed: 5mm/min

Distance between chucks: 50mm

Compared with Comparative Examples 1 and 2, since the irradiation distance of the first scanning in Example 1 was short, the diffusion of heat was suppressed, so that the groove depth per scanning can be increased.

Therefore, as in Comparative Example 1 and Comparative Example 1, Example 1 can shorten the total scanning time, and it can be confirmed that the joint strength which is obtained is higher than that of Comparative Composite Example 1.

Further, when Comparative Example 1 and Comparative Example 2 were compared, it was confirmed that when the scanning time was the same, a composite molded body having a joint strength of at least three times higher was obtained.

Therefore, by applying the manufacturing method of the present invention, the efficiency of laser processing (processing amount per unit time) can be greatly improved.

Claims (7)

A method for producing a composite molded body, which is a method for producing a composite molded body obtained by joining a metal molded body and a resin molded body, comprising: a first step of irradiating a laser beam to a joint surface of the metal molded body a step of forming a groove by a laser beam having a diameter of 10 to 200 μm to form a circle having a diameter of 20 to 1000 μm or a region of the same area, and forming a start point and an end point of the laser irradiation by one scan a groove, and repeating a plurality of scans to form a region surrounded by the groove; in the second step, the first step is repeated to form a plurality of regions surrounded by the groove; and in the third step, the inclusion is formed A portion of the metal molded body joint surface of the region surrounded by the groove is placed in the mold, and the resin to be the resin molded body is insert-molded. The method of manufacturing a composite formed body according to claim 1, wherein a region surrounded by the groove in the first step is a polygon selected from the group consisting of a circle, an ellipse, a triangle, a quadrangle, and a pentagon formed by a groove; Irregularly shaped area. A method of producing a composite formed body according to claim 1 or 2, wherein the second step is a step of forming a plurality of independent regions. The method of producing a composite formed article according to claim 1 or 2, wherein the second step is a step of forming all or a part of the regions adjacent to the plurality of regions. The method for producing a composite molded article according to claim 1 or 2, wherein the second step is a step of forming a plurality of regions on the entire joint surface of the metal formed body. The method for producing a composite formed article according to claim 1 or 2, wherein the second step is a step of forming a plurality of regions on a part of the joint surface of the metal formed body. The method of producing a composite formed body according to claim 1 or 2, wherein the joint surface of the metal formed body is a flat surface or a curved surface.