TW201607408A - Power converter casing, thermosetting resin composition, and power converter - Google Patents

Abstract

The provided chassis of a power conversion device is light-weight and has excellent reliability. This chassis of a power conversion device is configured from a resin-metal composite body formed by adhering a metal component and a resin component formed from a thermosetting resin, wherein the inner wall surface is configured from the aforementioned resin member.

Description

Housing of power conversion device, thermosetting resin composition, and power conversion device

The present invention relates to a casing, a thermosetting resin composition, and a power conversion device of a power conversion device.

The housing of the power conversion device such as an inverter or a converter is mostly composed of a metal member. Examples of the casing of the power conversion device composed of a metal member include the following.

Patent Document 1 describes a casing for a power conversion device, which is a metal casing that houses a power module, and the conductive member is connected to a specific position in the casing.

Patent Document 1: Japanese Laid-Open Patent Publication No. 2013-74752

However, since the metal case described in Patent Document 1 is a power conversion device that accommodates a high voltage, it is necessary to provide an edge surface distance (space) to ensure insulation. Therefore, when it is a case of a metal power conversion device, there is a large-sized member. Difficulties such as difficulty in weight reduction.

Therefore, the inventors of the present invention have conducted intensive studies in order to realize a casing of a power conversion device that is lighter and smaller than a conventional casing, and as a result of such a design policy, it has been found that it is effective to manufacture the resin member. The inner wall of the housing. However, when the casing of the power conversion device manufactured by laminating the resin member to the inner wall surface of the metal casing is formed, the problem that the mechanical strength is gradually lowered due to repeated use becomes conspicuous. In other words, the casing of the power conversion device in which the inner wall surface is formed by the resin member is required to be improved in terms of reliability in repeated use.

The present invention has been made in view of the above circumstances, and provides a casing of a power conversion device which is lightweight and excellent in reliability.

According to the present invention, there is provided a housing of a power conversion device comprising a resin-metal composite system in which a resin member made of a thermosetting resin is adhered to a metal member, and the power conversion device is The inner wall surface of the casing is composed of the above resin member.

Further, according to the present invention, there is provided a thermosetting resin composition for forming a resin member of a casing of a power conversion device, the casing of the power conversion device being bonded to the metal member by the resin member The resin metal composite is formed and the inner wall surface is composed of the above resin member, and the thermosetting resin composition contains a thermosetting resin.

Furthermore, according to the present invention, there is provided a power conversion device including a housing of the power conversion device.

According to the present invention, it is possible to provide a housing of a power conversion device which is lightweight and excellent in reliability. Further, at the same time, since the casing of the power conversion device of the present invention can be formed at one time, Therefore, it is expected that the steps can be reduced.

1‧‧‧Power conversion device

10‧‧‧shell

12‧‧‧Metal components

14‧‧‧Resin components

16‧‧‧Resin metal composite

103‧‧‧Closed surface

104‧‧‧Rough layer

201‧‧‧ recess

203‧‧‧ openings

205‧‧‧ bottom

701‧‧‧Indenter

703‧‧‧Support Desk

b‧‧‧Width

d ₁ , d ₂ , h‧‧‧ thickness

D1, D2‧‧‧ section width

D3‧‧ depth

F‧‧‧ force

L‧‧‧ distance between fulcrums

The above and other objects, features and advantages of the present invention will become more apparent from

Fig. 1 is a schematic view for explaining a casing of the power conversion device of the embodiment.

Fig. 2 is a schematic view for explaining an evaluation method of 1 million bending fatigue resistance.

Fig. 3 is a view for explaining the resin-metal composite of the embodiment.

Fig. 4 is a schematic view for explaining an example of a cross-sectional shape of a concave portion constituting a roughened layer on the surface of the metal member of the embodiment.

Hereinafter, embodiments of the present invention will be described using the drawings. In the drawings, the same components are denoted by the same reference numerals, and the description is omitted as appropriate.

"The housing of the power conversion device"

Fig. 1 is a schematic view for explaining a casing of the power conversion device of the embodiment.

As shown in Fig. 1, the casing 10 of the power conversion device according to the present embodiment is composed of a resin-metal composite in which a resin member 14 made of a thermosetting resin and a metal member 12 are adhered to each other. The inner wall surface of the casing 10 is composed of a resin member 14. As a result, the casing 10 of the power conversion device which is lightweight and excellent in reliability can be realized.

The casing 10 of the present embodiment is made of the resin member 14 (by heat as described above) The curable resin is composed of a resin metal composite in which the metal member 12 is in close contact with each other. In other words, the casing 10 of the present embodiment is formed of a member (resin metal composite) in which the joint interface between the resin member 14 and the metal member 12 is firmly joined. In addition, the metal member produced separately is simply not embedded in the resin metal composite of the present embodiment by simply inserting a resin member by assembly or the like. When the metal member produced separately is simply embedded in the resin member as the case of the power conversion device, stress is applied between the metal member and the resin member during use. Further, in the case where the above-described simply embedded casing is repeatedly used, it is considered that the stress is accumulated and the mechanical strength of the casing is gradually lowered.

Here, the resin-metal composite of the present embodiment is not particularly limited as long as the resin member 14 and the metal member 12 are in close contact with each other. However, it is preferable that the resin member 14 and the metal member 12 are joined without interposing an adhesive. It is more preferable if the resin member 14 and the metal member 12 are integrally formed. The resin member 14 and the metal member 12 have excellent joint strength even without interposing an adhesive. Therefore, the manufacturing steps of the resin metal composite can be simplified. In other words, in the resin-metal composite of the present embodiment, it is preferable that the resin member 14 and the metal member 12 are physically joined by an anchor effect or the like.

Further, since the casing 10 of the present embodiment is constituted by the resin member 14 as the inner wall surface thereof, unlike the conventional casing formed only of the metal member, the insulation can be ensured even without securing the edge surface distance (space). Thereby, the casing 10 of the present embodiment can be made compact with respect to a casing formed only of a metal member. Further, according to the present embodiment, since the resin member 14 constitutes the inner wall surface of the casing 10, it can be made lighter than the casing formed only of the metal member. In other words, the case 10 of the present embodiment can be reduced in size and weight as compared with a case in which only the metal member is formed, while maintaining the insulation property.

Further, the casing 10 of the present embodiment is composed of a resin-metal composite in which the resin member 14 made of a thermosetting resin and the metal member 12 are in close contact with each other. Therefore, it is possible to combine the advantages of the resin member 14 (excellent in light weight, excellent in insulation, excellent in rust resistance, and excellent in processing freedom) and the metal member 12 (excellent in electromagnetic wave shielding property, excellent in airtightness, and heat dissipation). The shell 10 of both excellent and the like). In particular, the case 10 of the present embodiment is formed by using not only the resin member 14 but also the metal member 12. Therefore, it is excellent in electromagnetic wave shielding property and can suppress the occurrence of noise.

Here, the power conversion device 1 housed in the casing 10 of the present embodiment is not particularly limited, but is preferably a power supply circuit that generates alternating current power (for reverse conversion) from direct current power, or has an inversion of the circuit. A power supply circuit that generates DC power (converted) from AC power, or a converter having the circuit.

Further, the resin-metal composite of the present embodiment preferably has the following bending fatigue resistance (hereinafter referred to as "1 million bending fatigue resistance"): the metal member 12 having the resin member 14 having a thickness d ₁ and a thickness d ₂ laminated thereon The test piece cut out so that the ratio d ₁ /d ₂ of the thickness of the resin material to the metal material is 3, and the following first state and the second state described below are alternately performed at a frequency of 30 Hz at a temperature of 25 ° C. When it is repeated 1 million times, it does not peel or break, and the first state is such that the exposed surface of the resin member faces upward on two support tables without stress; and the second state is the resin member. The center of the side surface is applied with a point stress of 140 MPa in the thickness direction to sink the center from the first state. Thus, the casing 10 having more excellent reliability can be obtained.

Here, whether or not the resin-metal composite has a bending fatigue resistance of 1 million times can be performed by applying a bending stress to a test piece made of a resin-metal composite. Evaluation. The details will be described below.

Fig. 2 is a view for explaining an evaluation method of 1 million bending fatigue resistance. First, a test piece of a rectangular parallelepiped composed of the resin metal composite 16 is prepared. The test piece is a contact surface 103 having one metal member 12 and a resin member 14, and the thickness d ₁ of the resin member 14 is three times the thickness d ₂ of the metal member 12 (d ₁ /d ₂ =3). Here, when d ₁ /d ₂ is 3, it is preferable that the thickness h, the width b, and the depth of the test piece are in accordance with JIS K 7171. In the test piece, the adhesion surface 103 of the metal member 12 and the resin member 14 is orthogonal to the thickness direction. The test piece can be prepared, for example, by cutting out from the casing 10.

The prepared test piece was placed on two support tables 703 (first state). The distance between the two support stands 703 is adjusted in advance by mounting the prepared test piece. The two support tables are arranged symmetrically with respect to the test piece. At this time, the surface on the side of the metal member 12 faces downward and contacts the support base 703. Further, the indenter 701 is brought into contact with the surface of the resin member 14 on the opposite side, and a bending stress of a single vibration of 140 MPa is applied in a direction perpendicular to the adhesion surface 103. The contact position of the indenter 701 and the test piece is set to a position equidistant from the contact position (fulcrum) of the two support stages 703 and the test piece. The application of the repeated stress was carried out at 25 ° C.

The magnitude of the bending stress σ [MPa] is expressed by σ = 3FL / 2bh ² . Here, F[N] is the force applied by the indenter 701 (unit: N), the distance between the L-support points (in mm), b is the width of the test piece (unit is mm), and h is the thickness of the test piece. (The unit is mm). The force F can be determined by applying the creep stress to the width of the test piece, the thickness, and the distance between the fulcrums so that the magnitude of the bending stress becomes 140 MPa, and the stress is applied.

By applying a stress of 140 MPa in this manner, the test piece was slightly bent into the shape of the center sink (second state). Then, the stress is stopped and the first shape is returned to the unstressed state. state. The first state and the second state were alternately repeated one million times at a frequency of 30 Hz. The test piece after applying a stress of 1 million times of the above-mentioned stress was observed, and it was confirmed that no peeling or fracture occurred. When neither peeling nor cracking occurred, it was evaluated as having 1 million bending fatigue resistance.

For example, the metal-resin composite 16 of the present embodiment can have a distance L between fulcrums of 64 mm, a width of the test piece of 80 mm, a depth of 10 mm, and a thickness h of 4.0 mm (thickness of the metal member 12 of 1.0 mm, resin) The thickness of the member 14 is 3.0 mm. The magnitude of the bending stress σ is 140 MPa, and it is confirmed that the bending fatigue resistance is 1 million times. However, as described above, the condition is not limited thereto.

Moreover, it is preferable that the resin metal composite of the present embodiment is subjected to heat treatment for 1000 cycles for the test piece obtained by the following treatment (it will stand at -40 ° C for 1 hour and then stand at 150 ° C for 1 hour). After the heat treatment is set to 1 cycle, the bending strength of the test piece measured according to JIS K6911 is 200 MPa or more; the above treatment is for laminating the resin member 14 having the thickness d ₁ and the metal member 12 having the thickness d ₂ and using the resin material. The test piece cut out at a ratio d ₁ /d ₂ of the thickness of the metal material to 3 was subjected to a firing treatment at 180 ° C for 8 hours. In the case where the casing 10 is formed of such a resin-metal composite, the casing 10 which is excellent in thermal durability and can be highly reliable in response to changes in temperature conditions can be realized. Moreover, the bending strength of the test piece measured according to the above conditions is more preferably 250 MPa or more, and still more preferably 300 MPa or more.

Moreover, it is preferable that the resin metal composite of the present embodiment is subjected to heat treatment for 1000 cycles for the test piece obtained by the following treatment (it will stand at -40 ° C for 1 hour and then stand at 150 ° C for 1 hour). After the heat treatment is set to 1 cycle, the test piece according to JIS K6911 has a flexural modulus of 20 GPa or more; and the above process is performed by laminating the resin member 14 having the thickness d ₁ of the base layer and the metal member 12 having the thickness d ₂ and A test piece obtained by firing a test piece cut at a ratio d ₁ /d ₂ of the thickness of the resin material and the metal material to 3 at 180 ° C for 8 hours. In the case where the casing 10 is formed of such a resin-metal composite, the casing 10 which is excellent in thermal durability and high in reliability in addition to various characteristics and capable of coping with changes in temperature conditions can be realized. Moreover, the bending elastic modulus of the test piece measured according to the above conditions is more preferably 22 GPa or more, and still more preferably 24 MPa or more.

In addition, the resin metal composite of the present embodiment is preferably a test piece having a size of 10 cm × 10 cm and a thickness of 4 mm which is produced by using the resin metal composite by a KEC (Kansai Electronic Industry Development Center) method. The shielding effect of the electromagnetic wave having a frequency of 1 GHz obtained by the measurement was 90 dB or more. In the case where the casing 10 is formed of such a resin-metal composite, it is possible to realize a casing 10 which is more excellent in terms of electromagnetic wave shielding properties in addition to various characteristics.

Further, in the resin metal composite, the linear expansion coefficient α _{R of the} resin member 14 in the range from 25 ° C to the glass transition temperature is within the range of 25 ° C of the metal member 12 to the above glass transition temperature of the resin member 14 The absolute value of the difference (α _{R -} α _M ) between the linear expansion coefficients α _M is preferably 25 ppm / ° C or less, more preferably 10 ppm / ° C or less. When the difference in the linear expansion coefficient is equal to or less than the above upper limit value, it is possible to suppress the thermal stress caused by the difference in linear expansion caused when the resin metal composite is exposed to a high temperature. Therefore, when the difference in the linear expansion coefficient is equal to or less than the above upper limit value, the bonding strength between the resin member 14 and the metal member 12 can be maintained even at a high temperature. In other words, when the difference in the linear expansion coefficient is equal to or less than the above upper limit value, the dimensional stability of the resin metal composite at a high temperature can be improved.

Further, in the present embodiment, when the linear expansion coefficient has an anisotropy, the average value thereof is expressed. For example, when the linear expansion coefficient of the flow direction (MD) is different from the linear expansion coefficient of the direction perpendicular thereto (TD) when the resin member 14 is in the form of a sheet, the average value thereof becomes the resin member 14 Linear expansion coefficient α _R .

<Metal member 12>

Fig. 3 is a view for explaining the resin-metal composite of the embodiment. This figure does not necessarily represent all or part of the construction of the housing 10. This drawing is a perspective view schematically showing an example of a molded article of a resin-metal composite constituting the casing 10.

The metal material constituting the metal member 12 is not particularly limited, and examples thereof include iron, stainless steel, aluminum, aluminum alloy, magnesium, magnesium alloy, copper, and copper alloy from the viewpoint of availability and price. These may be used alone or in combination of two or more. Among these, it is preferable to include the lightweight and high strength of the casing 10, the electromagnetic wave shielding property, the airtightness, and the rigidity of the metal material itself, such as rigidity. Aluminum, aluminum or stainless steel. From the viewpoint of improving the bonding strength between the resin member 14 and the metal member 12, the metal member 12 preferably has a rough layer 104 composed of fine concavities and convexities on the adhesion surface 103 of the metal member 12 and the resin member 14.

4 is a schematic view for explaining an example of a cross-sectional shape of a concave portion 201 constituting the roughened layer 104 on the surface of the metal member 12 of the present embodiment. Here, the roughened layer 104 refers to a region having a plurality of concave portions 201 provided on the surface of the metal member 12.

The thickness of the roughened layer 104 is preferably 3 μm or more and 40 μm or less, more preferably 4 μm or more and 32 μm or less, and particularly preferably 4 μm or more and 30 μm or less. When the thickness of the roughened layer 104 is within the above range, the bonding strength of the resin member 14 and the metal member 12 and the durability of bonding can be further improved. Here, in the present embodiment, the thickness of the roughened layer 104 indicates the depth D3 of the plurality of recesses 201 having the largest depth, which can be calculated according to a scanning electron microscope (SEM) photograph. Out.

The cross section of the concave portion 201 preferably has a shape in which at least a portion between the opening portion 203 and the bottom portion 205 of the concave portion 201 has a shape having a cross-sectional width D2 larger than the cross-sectional width D1 of the opening portion 203.

As shown in FIG. 4, the cross-sectional shape of the concave portion 201 is not particularly limited as long as D2 is larger than D1, and various shapes can be adopted. The cross-sectional shape of the concave portion 201 can be observed by, for example, a scanning electron microscope (SEM).

When the cross-sectional shape of the concave portion 201 is the above-described shape, the reason why the resin-metal composite having further excellent joint strength can be obtained is not necessarily clear, but it is considered that the reason is that the surface of the close-fitting surface 103 can more clearly express the resin member 14 and the metal member. The construction of the anchoring effect between 12.

When the cross-sectional shape of the concave portion 201 is the above-described shape, since the resin member 14 is caught between the opening portion 203 to the bottom portion 205 of the concave portion 201, the anchoring effect effectively functions. Therefore, it is considered that the joint strength of the resin member 14 and the metal member 12 and the durability of the joint are improved.

The average depth of the concave portion 201 is preferably 0.5 μm or more and 40 μm or less, and more preferably 1 μm or more and 30 μm or less. When the average depth of the concave portion 201 is equal to or less than the above-described upper limit value, the thermosetting resin composition (P) can sufficiently enter the depth of the concave portion 201, so that the resin member 14 and the metal member 12 can penetrate each other into the region. The strength and durability of the joint are further improved. When the average depth of the concave portion 201 is at least the above lower limit value, when the thermosetting resin composition (P) contains the filler (B), the ratio of the filler (B) existing inside the concave portion 201 can be increased. Therefore, the mechanical strength and the durability of the joining of the region in which the resin member 14 and the metal member 12 infiltrate can be improved. Therefore, if the average depth of the concave portion 201 is in the above-mentioned range In the periphery, the joint strength of the resin member 14 and the metal member 12 and the durability of the joint can be further improved.

The average depth of the concave portion 201 can be measured, for example, according to a scanning electron microscope (SEM) photograph in the following manner. First, the cross section of the rough layer 104 was photographed by a scanning electron microscope. 50 recesses 201 were arbitrarily selected from the observation images, and the depths thereof were measured. The value obtained by adding the total depth of the concave portions 201 and dividing by the number is set as the average depth.

The surface roughness Ra of the adhesion surface 103 of the metal member 12 is preferably 0.5 μm. The above is 40.0 μm or less, more preferably 1.0 μm or more and 20.0 μm or less, and particularly preferably 1.0 μm or more and 10.0 μm or less. When the surface roughness Ra is within the above range, the bonding strength between the resin member 14 and the metal member 12 can be further improved.

Moreover, the maximum height Rz of the adhesion surface 103 of the metal member 12 is preferably 1.0 μm or more and 40.0 μm or less, and more preferably 3.0 μm or more and 30.0 μm or less. When the maximum height Rz is within the above range, the joint strength of the resin member 14 and the metal member 12 and the durability of joining can be further improved. Further, Ra and Rz can be measured in accordance with JIS-B0601.

The ratio of the actual surface area to the apparent surface area measured by the nitrogen adsorption BET (Brunauer-Emmett-Teller) method of at least the adhesion surface 103 of the metal member 12 bonded to the resin member 14 (hereinafter, also referred to as The specific surface area is preferably 100 or more, more preferably 150 or more. When the specific surface area is at least the above lower limit value, the joint strength between the resin member 14 and the metal member 12 and the durability of joining can be further improved. Further, the specific surface area is preferably 400 or less, more preferably 380 or less, and still more preferably 300 or less. When the specific surface area is at most the above upper limit value, the joint strength between the resin member 14 and the metal member 12 and the durability of joining can be further improved.

Here, the apparent surface area in the present embodiment means a surface area assuming that the surface of the metal member 12 is smooth without unevenness. For example, in the case where the surface shape is a rectangle, it is represented by a longitudinal length × a horizontal length. On the other hand, the actual surface area measured by the nitrogen adsorption BET method in the present embodiment means the BET surface area obtained from the adsorption amount of nitrogen gas. For example, for a vacuum-dried sample to be measured, an automatic specific surface area/fine pore distribution measuring apparatus (BELSORPmini II, manufactured by BELL Japan) can be used to measure the amount of nitrogen adsorption desorption at a liquid nitrogen temperature, and based on the nitrogen adsorption desorption Calculated by quantity.

When the specific surface area is within the above range, the reason why the resin metal composite having excellent joint strength and joint durability can be obtained is not necessarily clear, but it is considered that the surface of the adhesive surface 103 with the resin member 14 is made available. The configuration of the anchoring effect between the resin member 14 and the metal member 12 is more clearly expressed.

When the specific surface area is at least the above lower limit value, the contact area between the resin member 14 and the metal member 12 is increased, and the area in which the resin member 14 and the metal member 12 infiltrate increases. As a result, it is considered that the area where the anchoring effect acts increases, and the joint strength of the resin member 14 and the metal member 12 and the durability of the joint are further improved.

On the other hand, when the specific surface area is too large, the ratio of the metal member 12 in the region in which the resin member 14 and the metal member 12 penetrate each other is lowered, so that the mechanical strength and the durability of the joint in the region are lowered. Therefore, when the specific surface area is equal to or less than the above upper limit value, the mechanical strength and the durability of joining of the region where the resin member 14 and the metal member 12 infiltrate are further improved, and as a result, the resin member 14 and the metal member can be obtained. The joint strength of 12 and the durability of the joint are further improved.

Based on the above, it is presumed that if the above specific surface area is within the above range, then The surface of the adhesion surface 103 of the member 14 is a structure which can more clearly express the balance of the anchoring effect between the resin member 14 and the metal member 12.

The metal member 12 is not particularly limited, but the gloss of the adhesion surface 103 bonded to at least the resin member 14 is preferably 0.1 or more, more preferably 0.5 or more, still more preferably 1 or more. When the glossiness is at least the above lower limit value, the bonding strength between the resin member 14 and the metal member 12 can be further improved. Further, the glossiness is preferably 30 or less, more preferably 20 or less. When the glossiness is at most the above upper limit value, the bonding strength between the resin member 14 and the metal member 12 can be further improved. Here, the glossiness in the present embodiment represents a value of a measurement angle of 60° (incident angle 60°, reflection angle 60°) measured in accordance with ASTM-D523. The gloss can be measured using, for example, a digital gloss meter (20°, 60°) (GM-26 type, manufactured by Murakami Color Research Institute Co., Ltd.).

When the glossiness is within the above range, the reason why the resin-metal composite which is more excellent in the joint strength can be obtained is not necessarily clear, but it is considered that the surface of the adhesion surface 103 of the resin member 14 is more disordered, and It becomes a structure which can express the anchoring effect between the resin member 14 and the metal member 12 more clearly.

The shape of the metal member 12 is not particularly limited as long as it has a shape of the adhesion surface 103 joined to the resin member 14. For example, it may be a sheet shape, a flat plate shape, a curved plate shape, a rod shape, a cylindrical shape, a block shape, or the like. . Further, it may be a structure composed of a combination of the above. The metal member 12 of such a shape can be obtained by processing the above-mentioned metal material by a known processing method.

Further, the shape of the adhesion surface 103 to be bonded to the resin member 14 is not particularly limited, and examples thereof include a flat surface and a curved surface.

Next, a method of roughening the surface of the metal member 12 to form the roughened layer 104 will be described.

The roughening layer 104 can be formed, for example, by chemically treating the surface of the metal member 12 with a surface treatment agent.

Here, the case where the surface of the metal member 12 is chemically treated using a surface treating agent is also itself carried out in the prior art. However, in the present embodiment, the height is controlled (1) the combination of the metal member and the chemical treatment agent, (2) the temperature and time of the chemical treatment, and (3) the post-treatment of the surface of the metal member after the chemical treatment. In order to obtain a resin-metal composite having 1 million bending fatigue resistance, it is particularly important to control such factors.

Hereinafter, an example of a method of forming the roughened layer 104 on the surface of the metal member 12 will be described. However, the method of forming the roughened layer 104 of the present embodiment is not limited to the following examples.

First, (1) a combination of a metal member and a surface treatment agent is selected.

When a metal member 12 made of iron or stainless steel is used, it is preferred to select an aqueous solution obtained by combining an inorganic acid, a chloride ion source, a second copper ion source, or a thiol compound as a surface treatment agent.

In the case of using the metal member 12 composed of aluminum or an aluminum alloy, it is preferred to select an aqueous solution in which an alkali metal source, an amphoteric metal ion source, a nitrate ion source, and a thio compound are combined as a surface treatment agent as needed.

In the case of using the metal member 12 composed of magnesium or a magnesium alloy, an alkali metal source is used as the surface treatment agent, and an aqueous solution of sodium hydroxide is preferably selected.

In the case of using the metal member 12 composed of copper or a copper alloy, it is preferred to use an organic acid selected from the group consisting of inorganic acids such as nitric acid and sulfuric acid, unsaturated acid, persulfate, hydrogen peroxide, imidazole and derivatives thereof. , tetrazole and its derivatives, aminotetrazole and its derivatives, amine triazoles and their derivatives, azoles, pyridine derivatives, three ,three Derivatives, alkanolamines, alkylamine derivatives, polyalkylene glycols, sugar alcohols, second copper ion source, chloride ion source, phosphonic acid chelating agent oxidizing agent, N,N-bis(2-hydroxyethyl) An aqueous solution of at least one of benzyl-N-cyclohexylamine is used as a surface treatment agent.

Then, (2) the metal member 12 is immersed in the surface treatment agent to chemically treat the surface of the metal member 12. At this time, the treatment temperature is, for example, 30 °C. Further, the processing time is appropriately determined depending on the material or surface state of the selected metal member 12, the type or concentration of the surface treatment agent, the processing temperature, and the like, and is, for example, 30 to 300 seconds. At this time, it is important that the etching amount in the depth direction of the metal member 12 is preferably 3 μm or more, and more preferably 5 μm or more. The amount of etching in the depth direction of the metal member 12 can be calculated and evaluated based on the weight, specific gravity, and surface area of the dissolved metal member 12. The amount of etching in the depth direction can be adjusted depending on the kind or concentration of the surface treatment agent, the processing temperature, the processing time, and the like.

In the present embodiment, the thickness of the roughened layer 104, the average depth of the concave portion 201, Ra, Rz, and the like can be adjusted by adjusting the amount of etching in the depth direction.

Finally, (3) the surface of the chemically treated metal member 12 is post-treated. First, the surface of the metal member 12 is washed with water and dried. Then, the surface of the metal member 12 subjected to the chemical treatment is treated with an aqueous solution of nitric acid or the like.

According to the above procedure, the metal member 12 having the roughened layer 104 of the present embodiment can be obtained.

<Resin member 14>

Next, the resin member 14 of the present embodiment will be described.

The resin member 14 is obtained by curing the thermosetting resin composition (P).

The thermosetting resin composition (P) contains a thermosetting resin (A), and as the thermosetting resin (A), for example, a phenol resin, an epoxy resin, an unsaturated polyester resin, or diene phthalate can be used. Diallyl phthalate resin, melamine resin, oxetane resin, maleic imine resin, urea (urea) resin, polyurethane resin, polyoxyl resin, with benzoic acid Ring resin, cyanate resin, and the like. These may be used alone or in combination of two or more.

Among these, it is preferable to use a resin selected from the group consisting of a phenol resin and a ring in terms of characteristics of the resin material itself such as heat resistance, workability, mechanical properties, adhesion, and rust resistance. One or more thermosetting resin compositions of the group consisting of an oxygen resin and an unsaturated polyester resin.

When the total amount of the resin member 14 is 100 parts by mass, the content of the thermosetting resin (A) is preferably 15 parts by mass or more and 60 parts by mass or less, more preferably 25 parts by mass or more and 50 parts by mass or less.

Examples of the phenol resin include a novolac type phenol resin such as a phenol novolak resin, a cresol novolak resin, and a bisphenol A novolak resin; a methylol type resol resin and a dimethylene ether type soluble; A phenolic resin, a molten oil in a tung oil, a linseed oil, a walnut oil, or the like, a molten novolac type phenol resin such as a phenolic phenol resin; and an arylalkylene type phenol resin. These may be used alone or in combination of two or more.

Among the above phenol resins, it is preferred to use a novolac type phenol resin or a resol type phenol resin, and more preferably a resol type phenol, for the reasons of easiness of acquisition, low cost, and good workability of roll kneading. Resin. When a novolac type phenol resin is used as a main component, hexamethylenetetramine is generally used as a curing agent, and a corrosive gas such as ammonia gas is generated when the novolac type phenol resin is cured. Therefore, since the parts provided in the inside of the casing 10 are corroded by this, it is preferable to use a resol type phenol resin as compared with the novolac type phenol resin.

Further, a novolak type phenol resin and a novolak type phenol resin may be used in combination. Thereby, it can be improved The strength of the resin member 14 can also improve the toughness.

The thermosetting resin composition (P) contains a filler (B) from the viewpoint of improving the mechanical strength of the resin member 14. However, in the present embodiment, the following elastomer (D) is excluded from the filler (B).

When the total amount of the resin member 14 is 100 parts by mass, the content of the filler (B) is preferably 30 parts by mass or more and 80 parts by mass or less, more preferably 40 parts by mass or more and 70 parts by mass or less. By setting the content of the filler (B) within the above range, the workability of the thermosetting resin composition (P) can be improved, and the mechanical strength of the obtained resin member 14 can be further improved. Thereby, a resin-metal composite body in which the bonding strength between the resin member 14 and the metal member 12 is further improved can be obtained. Further, by adjusting the kind or content of the filler (B), the value of the linear expansion coefficient α _R of the obtained resin member 14 can be adjusted.

Examples of the filler (B) include a fibrous filler, a particulate filler, and a plate filler. Here, the fibrous filler is a fibrous filler material. The plate-shaped filling material is a filling material whose shape is a plate shape. The particulate filler material is a filler material having a shape other than a fibrous shape or a plate shape which is not fixed in shape.

Examples of the fibrous filler include glass fiber, carbon fiber, asbestos fiber, metal fiber, wallastonite, attapulgite, sepiolite, rock wool, and aluminum borate whisker. Fibrous inorganic fillers such as crystal, potassium titanate fiber, calcium carbonate whisker, titanium oxide whisker, ceramic fiber; aromatic polyamide fiber, polyimine fiber, poly(p-phenylene benzoate) A fibrous organic filler such as azole. These may be used alone or in combination of two or more.

Moreover, as the plate-shaped filler or the particulate filler, for example, Talc, kaolin clay, calcium carbonate, zinc oxide, calcium citrate hydrate, mica, glass cullet, glass powder, magnesium carbonate, cerium oxide, titanium oxide, aluminum oxide, aluminum hydroxide, magnesium hydroxide, barium sulfate, sulfuric acid Calcium, calcium sulfite, zinc borate, barium metaborate, aluminum borate, calcium borate, sodium borate, aluminum nitride, boron nitride, tantalum nitride, pulverized material of the above fibrous filler, and the like. These may be used alone or in combination of two or more.

When the entirety of the filler (B) is 100 parts by mass, the filler (B) preferably contains an average particle diameter of more than 5 μm in a weight-based particle size distribution measured by a laser diffraction scattering particle size distribution measurement method. The filler (B1) is 70 parts by mass or more and 99 parts by mass or less, more preferably 85 parts by mass or more and 98 parts by mass or less. Thereby, the workability of the thermosetting resin composition (P) can be improved, and the mechanical strength of the obtained resin member 14 can be further improved. The upper limit of the average particle diameter of the filler (B1) is not particularly limited, and is, for example, 100 μm or less.

The filler (B1) is more preferably a fibrous filler or a plate-like filler having an average major axis of 5 μm or more and 50 mm or less and an average aspect ratio of 1 or more and 1,000 or less.

The average long diameter and the average aspect ratio of the filler (B1) can be measured, for example, from SEM photographs in the following manner. First, a plurality of fibrous filler materials or plate-shaped filler materials were imaged using a scanning electron microscope. 50 fibrous filler materials or plate-shaped filler materials are arbitrarily selected from the observation images, and the long diameters thereof are measured (in the case of the fibrous filler material, the fiber length is long, and in the case of the plate-shaped filler material, the plane is flat). The long diameter dimension of the direction) and the short diameter (the fiber diameter in the case of the fibrous filler material and the thickness direction in the case of the plate filler material). The value obtained by adding all the long diameters and dividing by the number is set as the average major diameter. Similarly, the value obtained by adding all the short diameters and dividing by the number is set as the average short diameter. Moreover, the average long diameter is relative to the flat The average short diameter is set to the average aspect ratio.

The filler (B1) is preferably one or more selected from the group consisting of glass fibers, carbon fibers, glass particles, and calcium carbonate. If such a filler (B1) is used, the mechanical strength of the resin member 14 can be particularly improved.

Further, when the entire filler (B) is 100 parts by mass, the filler (B) preferably contains an average particle diameter in a weight-based particle size distribution measured by a laser diffraction scattering particle size distribution measurement method. The filler (B2) of 0.1 μm or more and 5 μm or less is contained in an amount of 1 part by mass or more and 30 parts by mass or less, more preferably 2 parts by mass or more and 15 parts by mass or less. Thereby, the filling material (B) can be sufficiently present inside the concave portion 201. As a result, the mechanical strength of the region in which the resin member 14 and the metal member 12 infiltrate can be further improved.

More preferably, the filler (B2) comprises a fibrous filler or a plate filler, and the average diameter of the fibrous filler or the plate filler is preferably 0.1 μm or more and 100 μm or less, more preferably 0.2. The average aspect ratio is preferably 1 or more and 50 or less, more preferably 1 or more and 40 or less, in the range of μm or more and 50 μm or less.

The average long diameter and the average aspect ratio of the filler (B2) can be measured, for example, from the SEM photograph in the following manner. First, a plurality of fibrous filler materials or plate-shaped filler materials were imaged using a scanning electron microscope. 50 fibrous filler materials or plate-shaped filler materials are arbitrarily selected from the observation images, and the long diameters thereof are measured (in the case of the fibrous filler material, the fiber length is long, and in the case of the plate-shaped filler material, the plane is flat). The long diameter dimension of the direction) and the short diameter (the fiber diameter in the case of the fibrous filler material and the thickness direction in the case of the plate filler material). The value obtained by adding all the long diameters and dividing by the number is set as the average major diameter. Similarly, the value obtained by adding all the short diameters and dividing by the number is set as the average short diameter. Moreover, the average long diameter is relative to the flat The average short diameter is set to the average aspect ratio.

The filler (B2) is preferably one selected from the group consisting of ash, kaolin, talc, calcium carbonate, zinc oxide, calcium citrate hydrate, aluminum borate whisker, and potassium titanate fiber. 2 or more types.

Further, the thermosetting resin composition (P) preferably contains a solid lubricant as a filler (B). The solid lubricant is preferably one or more selected from the group consisting of, for example, graphite, carbon fiber, and fluororesin. By containing a solid lubricant, the coefficient of friction of the resin member 14 is lowered.

Further, the filler (B) may be subjected to surface treatment using a coupling agent such as the following decane coupling agent (C).

The thermosetting resin composition (P) may further contain a decane coupling agent (C). By containing the decane coupling agent (C), the adhesion between the resin member 14 and the metal member 12 can be improved. Moreover, by including the decane coupling agent (C), the affinity between the thermosetting resin (A) and the filler (B) is improved, and as a result, the mechanical strength of the resin member 14 can be further improved.

The content of the decane coupling agent (C) is not particularly limited as long as it depends on the specific surface area of the filler (B), but is preferably 0.01 parts by mass or more and 4.0 parts by mass or less based on 100 parts by mass of the filler (B). More preferably, it is 0.1 mass part or more and 1.0 mass part or less. When the content of the decane coupling agent (C) is within the above range, the filler (B) can be sufficiently coated, and the mechanical strength of the resin member 14 can be further improved.

Examples of the decane coupling agent (C) include γ-glycidoxypropyltrimethoxydecane, γ-glycidoxypropyltriethoxydecane, and β-(3,4-epoxycyclohexyl). An alkoxydecane compound containing an epoxy group such as ethyltrimethoxydecane; γ-mercaptopropyltrimethoxy a mercapto-containing alkoxydecane compound such as decane, γ-mercaptopropyltriethoxydecane; γ-ureidopropyltriethoxydecane, γ-ureidopropyltrimethoxydecane, γ-(2 Urea-based alkoxydecane compound such as ureidoethyl)aminopropyltrimethoxydecane; γ-isocyanatepropyltriethoxydecane, γ-isocyanatepropyltrimethoxydecane, γ- Isocyanate propyl methyl dimethoxy decane, γ-isocyanate propyl methyl diethoxy decane, γ-isocyanate propyl ethyl dimethoxy decane, γ-isocyanate propyl ethyl di An alkoxydecane compound containing an isocyanate group such as oxydecane or γ-isocyanatepropyltrichlorodecane; γ-aminopropyltriethoxydecane, γ-(2-aminoethyl)aminopropyl An alkoxy alkane compound containing an amino group such as methyl dimethoxydecane, γ-(2-aminoethyl)aminopropyltrimethoxydecane, γ-aminopropyltrimethoxydecane; and γ a hydroxyl group-containing alkoxydecane compound such as hydroxypropyltrimethoxydecane or γ-hydroxypropyltriethoxysilane.

These may be used alone or in combination of two or more.

The thermosetting resin composition (P) of the present embodiment may further contain an elastomer (D) from the viewpoint of improving the toughness of the resin member 14. However, in the present embodiment, the filler (B) is excluded from the elastomer (D).

When the total amount of the resin member 14 is 100 parts by mass, the content of the elastomer (D) is preferably 1 part by mass or more and 10 parts by mass or less, more preferably 1.5 parts by mass or more and 7 parts by mass or less. By setting the content of the elastomer (D) within the above range, the mechanical strength of the resin member 14 can be maintained, and the toughness of the resin member 14 can be further improved. Thereby, a resin-metal composite body in which the bonding strength between the resin member 14 and the metal member 12 is further improved can be obtained.

Examples of the elastomer (D) include unmodified polyvinyl acetate, carboxylic acid modified polyvinyl acetate, polyvinyl butyral, natural rubber, and isoprene rubber. Styrene-butadiene rubber, butadiene rubber, chloroprene rubber, butyl rubber, ethylene-propylene rubber, acrylic rubber, styrene-isoprene rubber, acrylonitrile-butadiene rubber, amine ester Urethane gum, silicone rubber, fluorine rubber, etc. These may be used alone or in combination of two or more. Among them, preferred are unmodified polyvinyl acetate, carboxylic acid modified polyvinyl acetate, acrylic rubber, acrylonitrile-butadiene rubber, and polyvinyl butyral. When these elastomers (D) are used, the toughness of the resin member 14 can be particularly improved.

The method for producing the thermosetting resin composition (P) is not particularly limited, and it can be usually produced by a known method. For example, the following methods can be mentioned. First, a filler (B), a decane coupling agent (C), an elastomer (D), a hardener, a hardening aid, a mold release agent, a pigment, a flame retardant, and the like are blended in the thermosetting resin (A) as needed. A weathering agent, an antioxidant, a plasticizer, a lubricant, a slip agent, a foaming agent, and the like are uniformly mixed. Then, the obtained mixture is subjected to heat-melting and kneading by a kneading device such as a roll, a two-way kneader, or a twin-screw extruder alone or by a combination of a roll and another kneading device. Finally, the obtained mixture is granulated or pulverized, whereby a thermosetting resin composition (P) is obtained.

The linear expansion coefficient α _{R of the} resin member 14 in the range from 25 ° C to the glass transition temperature is preferably 10 ppm / ° C or more and 50 ppm / ° C or less, more preferably 15 ppm / ° C or more and 45 ppm / ° C or less. When the linear expansion coefficient α _{R is} within the above range, the reliability of the temperature cycle of the resin metal composite can be further improved.

The density of the resin member 14 is preferably 2.5 g/cm ³ or less, and more preferably 2.0 g/cm ³ or less from the viewpoint of weight reduction.

Moreover, the moisture-resistant dielectric breakdown strength measured by the resin member 14 after 1000 hours of moisture resistance treatment at 40 ° C and 90% RH is preferably 5 MV/m or more, and more preferably 7 MV/m. on. Thereby, the reliability of the temperature cycle of the resin metal composite can be further improved.

The thermal conductivity of the resin member 14 is preferably 90 W/(m.K) or less, more preferably 1 W/(m.K) or less. When it is less than or equal to the above upper limit, the heat insulating property of the power conversion device 1 is improved. The thermal conductivity can be measured by the laser flash method. Further, in the case where the thermal conductivity has an anisotropy, it is a thermal conductivity in a direction perpendicular to the adhesion surface 103 of the metal member 12 and the resin member 14.

In the case of using the thermosetting resin composition (P) containing the filler (B), the filler (B) is present inside the concave portion 201, and the filler (B) present in the concave portion 201 is scanned by an electron microscope. The average long diameter of the image analysis of the photograph is preferably 0.1 μm or more and 5.0 μm or less, more preferably 0.2 μm or more and 4 μm or less. Thereby, the mechanical strength of the region in which the resin member 14 and the metal member 12 infiltrate can be further improved.

Moreover, the average aspect ratio of the filler (B) existing inside the concave portion 201 is preferably 1 or more and 50 or less, more preferably 1 or more and 40 or less.

The average major axis and the average aspect ratio of the filler (B) present inside the concave portion 201 can be measured according to the SEM photograph in the following manner. First, the cross section of the rough layer 104 was photographed by a scanning electron microscope. 50 filler materials (B) existing in the inside of the concave portion 201 are arbitrarily selected from the observed images, and the long diameters thereof are measured (in the case of the fibrous filler material, the fiber length is long, and in the case of the plate-shaped filler material) In the case of the fibrous filler material, the fiber diameter is in the case of the fibrous filler material and the thickness direction in the case of the plate filler material. The value obtained by adding all the long diameters and dividing by the number is set as the average major diameter. Similarly, the value obtained by adding all the short diameters and dividing by the number is set as the average short diameter. Further, the average major axis is set to an average aspect ratio with respect to the average minor axis.

Further, the filler (B) present inside the recess 201 is preferably selected from One or more of a group consisting of a limestone, a kaolin clay, a talc, a calcium carbonate, a zinc oxide, a calcium silicate hydrate, an aluminum borate whisker, and a potassium titanate fiber.

Further, when the resin member 14 contains the elastic body (D), the resin member 14 is preferably an island structure, and the elastomer (D) preferably has an island phase.

According to this configuration, the toughness of the resin member 14 can be improved, and the impact resistance of the resin metal composite can be improved. Therefore, even if an impact is applied to the resin metal composite from the outside, the bonding strength between the resin member 14 and the metal member 12 can be maintained.

The island structure can be observed using a scanning electron microscope photograph.

The average diameter of the island phase obtained by image analysis of a scanning electron microscope photograph is preferably 0.1 μm or more and 100 μm or less, more preferably 0.2 μm or more and 30 μm or less. When the average diameter of the island phase is within the above range, the toughness of the resin member 14 can be further improved, and the impact resistance of the resin metal composite can be further improved.

The average diameter of the island phase can be measured according to a scanning electron microscope (SEM) photograph in the following manner. First, the cross section of the resin member 14 was imaged by a scanning electron microscope. From the observation image, 50 island phases existing in the resin member 14 were arbitrarily selected, and the diameters thereof were measured. The value obtained by adding all the diameters of the island phases and dividing by the number is set as the average diameter.

<Method of Manufacturing Housing of Power Conversion Device>

The method for producing the casing 10 of the present embodiment is not particularly limited as long as it is a method of molding the resin metal composite so that the resin member 14 and the metal member 12 are in close contact with each other. Examples of the method of molding such a resin metal composite include an injection molding method, a transfer molding method, a compression molding method, and an injection compression molding method. However, when the casing 10 composed of a resin-metal composite having 1 million bending fatigue resistance is produced, it is difficult to obtain it by the above-described general molding method.

Specifically, the casing 10 composed of a resin-metal composite having 1 million bending fatigue resistance focuses on various factors such as height control of the following two conditions.

(1) Selection of resin materials (thermosetting resin, combination of curing agent and additive, etc.)

(2) Selection of metal materials (types of metals, setting of various conditions for surface treatment, etc.)

Further, in the embodiment, an example of a method of manufacturing the casing 10 of the power conversion device according to the present embodiment will be specifically described.

Further, the power conversion device 1 of the present embodiment is manufactured by combining the casing 10 with other components. Other parts can usually be manufactured by a known method.

"thermosetting resin composition"

The thermosetting resin composition of the present embodiment is used to form a resin member of a casing of a power conversion device, and the thermosetting resin composition contains a thermosetting resin; the casing of the power conversion device is The resin member 14 is formed of a resin metal composite in which the resin member 14 and the metal member 12 are joined, and the inner wall surface is composed of the resin member 14.

Power Conversion Device

The power conversion device according to the embodiment includes a casing of the power conversion device.

Although the embodiments of the present invention have been described above with reference to the drawings, the various configurations other than the above may be employed as exemplified by the present invention.

Example

Hereinafter, the present embodiment will be described in detail with reference to examples and comparative examples. Furthermore, the present embodiment is not limited to the description of the embodiments.

(Example 1)

<Preparation of Thermosetting Resin Composition (P1)>

34.3 parts by mass of a novolak-type phenol resin (PR-51305, manufactured by SUMITOMO BAKELITE Co., Ltd.), 6.0 parts by mass of hexamethylenetetramine as a curing agent, and 57.1 parts by mass of a glass fiber (manufactured by Nitto Bose Co., Ltd.) as a filler. 0.2 parts by mass of γ-aminopropyltriethoxydecane (manufactured by Shin-Etsu Chemical Co., Ltd.) as a decane coupling agent, 0.5 parts by mass of magnesium oxide (manufactured by Shinto Chemical Industry Co., Ltd.) as a curing aid, and other components such as a lubricant. The mass fractions were dry-mixed, and the mixture was melt-kneaded by a heating roll at 90 ° C to pulverize the sheet into a sheet and cooled to obtain a pellet-shaped thermosetting resin composition (P1).

<Preparation of metal members>

As a metal sheet which was not subjected to surface treatment, a metal sheet A (80 mm × 10 mm, thickness 1.0 mm, density 2.68 g/cm ³ , thermal conductivity 138 W) of aluminum alloy A5052 whose surface was sufficiently ground by #4000 abrasive paper was prepared. /(m.K)). An aqueous solution of potassium hydroxide (16 parts by mass), zinc chloride (5 parts by mass), sodium nitrate (5 parts by mass), and sodium thiosulfate (13 parts by mass) was prepared. The metal sheet A was immersed in the obtained aqueous solution (30 ° C) and shaken to dissolve it in the depth direction by 15 μm (calculated according to the weight reduced by aluminum). Then, it was washed with water, and immersed in 35 parts by mass of an aqueous nitric acid solution (30 ° C) for 20 seconds. Thereafter, it was washed with water and dried to obtain a metal sheet 1.

<Production of Resin Metal Composite>

The resin-metal composite 1 was produced using the obtained thermosetting resin composition (P1) and the metal sheet 1. Specifically, it is produced in the following order. First, the metal sheet 1 having a thickness of 1 mm is placed in a mold without being fixed. Then, the thermosetting resin composition (P1) is heated so as to have a thickness of 3 mm after hardening, and a specific amount is injected into the mold. At this time, the metal sheet 1 is pressed against the inner wall of the mold by the fluid pressure of the thermosetting resin composition (P). Finally, the thermosetting resin composition (P1) is cured by compression molding, whereby a two-layer sheet of a resin member sheet (resin member) having a thickness of 3 mm and a metal sheet 1 (metal member) having a thickness of 1 mm is obtained. Resin metal composite 1 (composite member). This resin metal composite 1 was used as the test piece 1. Further, the compression molding conditions were set to an effective pressure of 20 MPa, a mold temperature of 175 ° C, and a curing time of 3 minutes.

<Production of the casing>

A casing of a power conversion device composed of a resin metal composite was produced under the same conditions as those for producing the test piece 1. Then, the power conversion device is housed in the manufactured casing. Further, the components related to the power conversion device (inverter) housed in the casing are prepared by a generally known method.

The following measurement and evaluation were carried out using the thermosetting resin composition, the metal member, the resin metal composite or the casing obtained by the above method.

(Example 2)

The resin-metal composite 2 was produced in the same manner as in Example 1 except that the thermosetting resin composition (P2) was used instead of the thermosetting resin composition (P1). This resin-metal composite 2 was used as the test piece 2, and the following measurement and evaluation were performed.

<Adjustment of Thermosetting Resin Composition (P2)>

Phenol (p) and formaldehyde (f) are added in a reaction tank equipped with a reflux condenser, a heating device, and a vacuum dehydration device at a molar ratio (f/p) = 1.7, and 100 parts by mass of phenol is added thereto. 0.5 parts by mass of zinc acetate, the pH of the reaction system was adjusted to 5.5 and a reflux reaction was carried out for 3 hours. Thereafter, the unreacted phenol was removed by steam distillation at a vacuum of 100 Torr and a temperature of 100 ° C for 2 hours, and further, the mixture was mixed at a vacuum of 100 Torr and a temperature of 115 ° C. The solid matter having a number average molecular weight of 800 bis methylene ether type obtained by reacting the compound for 1 hour is used as a resol type phenol resin.

25.3 parts by mass of the obtained novolac type phenol resin, 10.7 parts by mass of a novolac type phenol resin (PR-51305, manufactured by SUMITOMO BAKELITE Co., Ltd.), and 53.5 parts by mass of a glass fiber (manufactured by Nitto Bose Co., Ltd.) as a filler 4.9 parts by mass of a filler clay (manufactured by ENGELHARD Co., Ltd.), γ-aminopropyltriethoxydecane (manufactured by Shin-Etsu Chemical Co., Ltd.) as a decane coupling agent, 0.5 parts by mass of slaked lime as a hardening aid (Chichibu Lime Industries Co., Ltd.) Manufactured) 1.8 parts by mass, 3.3 parts by mass of other components such as a lubricant, and dry-mixed, and the mixture was melt-kneaded by a heating roll at 90 ° C to pulverize the product into a sheet shape and cooled to obtain a granulated heat hardening. Resin composition (P2).

(Example 3)

The thermosetting resin composition (P3) was prepared so as to be blended as described in the following Table 1, except that the resin metal composite 3 was produced in the same manner as in Example 1. The resin metal composite 3 was used as the test piece 3, and the following measurement and evaluation were performed.

(Example 4)

The thermosetting resin composition (P4) was prepared so as to be blended as described in the following Table 2. The resin metal composite 4 was produced in the same manner as in Example 1 except for the above. This resin-metal composite 4 was used as the test piece 4, and the following measurement and evaluation were performed.

(Example 5)

The thermosetting resin composition (P5) was prepared so as to be blended as described in the following Table 2. The resin metal composite 5 was produced in the same manner as in Example 1 except for the above. This resin-metal composite 5 was used as the test piece 5, and the following measurement and evaluation were performed.

(Example 6)

The thermosetting resin composition (P6) was prepared so as to be blended as described in the following Table 2. The resin metal composite 6 was produced in the same manner as in Example 1 except for the above. This resin-metal composite 6 was used as the test piece 6, and the following measurement and evaluation were performed.

(Example 7)

The thermosetting resin composition (P7) was prepared so as to be blended as described in the following Table 2. The resin metal composite 7 was produced in the same manner as in Example 1 except for the above. The resin metal composite 7 was used as the test piece 7 and subjected to the following measurement and evaluation.

(Comparative Example 1)

A test piece containing no resin member was prepared. Specifically, as a metal sheet which was not subjected to surface treatment, a metal sheet D (80 mm × 10 mm, thickness 4.0 mm, density 2.68 g/cm ^{3 )} of aluminum alloy A5052 whose surface was sufficiently ground by #4000 abrasive paper was prepared. The thermal conductivity was 138 W/(m.K)) and it was used as the test piece 8.

The test piece 8 was subjected to the following measurement and evaluation.

The casing composed of only the metal member of the comparative example was produced by processing the aluminum alloy A5052 by a known method.

(Comparative Example 2)

A test piece containing no metal members was produced. Specifically, the thermosetting resin composition (P1) is heated, and a specific amount is injected into the mold, and then the thermosetting resin composition (P1) is cured by compression molding, thereby obtaining a thickness of 80 mm × 10 mm. A 4.0 mm test piece 9 composed only of a resin member. Further, the compression molding conditions were set to an effective pressure of 20 MPa, a mold temperature of 175 ° C, and a curing time of 3 minutes.

The following measurement and evaluation were performed on the test piece 9.

(Comparative Example 3)

The metal sheet A which was not subjected to surface treatment used in Example 1 was used instead of the metal sheet 1, and the case made of the metal sheet A was embedded in a case made of a thermosetting resin composition (P1). A resin metal composite 8 was produced in the same manner as in Example 1 except for the casing of the power conversion device. This resin-metal composite 8 was used as the test piece 10, and the following measurement and evaluation were performed.

The measurement and evaluation as described below were carried out on the obtained thermosetting resin composition, metal member, resin metal composite or case.

Density of resin member: A resin sample having a thickness of 2 mm was cut out from the resin member sheet, and the density of the resin member was measured by an underwater displacement method. The unit is set to g/cm ³ .

Specific surface area of the metal member: After the sample to be measured was vacuum-dried at 120 ° C for 6 hours, the amount of nitrogen adsorption desorption at the liquid nitrogen temperature was measured using an automatic specific surface area/fine pore distribution measuring apparatus (BELSORPmini II, manufactured by BELL Japan). . The actual surface area measured by the nitrogen adsorption BET method was calculated from the BET curve. The specific surface area was calculated by dividing the actual surface area obtained by the nitrogen adsorption BET method by the apparent surface area.

Gloss of the surface of the metal member: using a digital gloss meter (20°, 60°) (GM-26 type, manufactured by Murakami Color Research Institute Co., Ltd.), measuring angle 60° according to ASTM-D523 (incident angle 60°, The reflection angle was 60°) and the gloss of the surface of the metal member was measured.

1 million bending fatigue resistance: The test piece was evaluated for 1 million bending fatigue resistance by the method described in the embodiment. The two fulcrums were brought into contact with the surface of the metal member side of the test piece, and the ram was brought into contact with the center of the surface on the side of the resin member. In the 25 ° C environment, will repeat The frequency of the stress was set to 30 Hz, and the distance L between the fulcrums was set to 64 mm, and a bending stress of 140 MPa was continuously applied to the test piece for 1 million times. The case where neither 1 million times of stress cracking nor peeling was applied was evaluated as ○, and the case where cracking or peeling occurred during the application of 1 million times of the stress was evaluated as ×.

Bending strength after 1000 cycles: First, the test piece was fired at 180 ° C for 8 hours. The test piece after the firing obtained in this manner was subjected to heat treatment at 1000 ° C for 1 hour and then at 150 ° C for 1 hour. Next, the obtained test piece was measured for its bending strength in accordance with JIS K6911. The unit system is set to MPa. Further, in the following table, the case where cracking or peeling occurred during the heat treatment for 1000 cycles was recorded as ×.

Flexural modulus after 1000 cycles: First, the test piece was fired at 180 ° C for 8 hours. The test piece after the firing obtained in this manner was subjected to heat treatment at 1000 ° C for 1 hour and then at 150 ° C for 1 hour. Next, with respect to the obtained test piece, the bending elastic modulus thereof was measured in accordance with JIS K6911. The unit is set to GPa. Further, in the following table, the case where cracking or peeling occurred during the heat treatment for 1000 cycles was recorded as ×.

Electromagnetic wave shielding effect: A test piece having a size of 10 cm × 10 cm and a thickness of 4 mm was cut out from the produced resin metal composite. The cut test piece was used, and the electromagnetic wave shielding ratio of the resin metal composite was measured in accordance with the KEC method. The unit is set to dB.

Moisture-resistant dielectric breakdown strength: A test piece having a size of 100 mm × 100 mm and a thickness of 2 mm was cut out from the produced resin metal composite. Next, the test piece cut out was subjected to a moisture-resistant treatment for 1000 hours at 40 ° C and 90% RH. The thus obtained moisture-resistant test piece was placed in a bath to which an insulating oil was added. Next, the central portion of the test piece is sandwiched between the upper and lower electrodes. After fixing the center lines of the two electrodes in a uniform manner, the wires are connected to the electrodes to form a test circuit. A voltage was applied to the formed circuit, and the breakdown voltage at the time of destruction of the test piece was measured. Furthermore, the application of the voltage increases the fixed speed of the dielectric breakdown of the sample from an average of 10 to 20 seconds from zero. Then, the moisture-resistant dielectric breakdown strength was calculated by dividing the measured value of the breakdown voltage by the measured average thickness of the test piece. The unit is set to MV/m.

Reliability evaluation of the casing: First, the casing of the power conversion device shown in Fig. 1 was produced. Then, an attempt was made to actually evaluate the reliability of the obtained casing of the power conversion device obtained.

The evaluation criteria are as follows.

○: Even after using it for many times, even minor damage has not occurred, and there is no problem in actual use.

△: After being used for many times, there is slight damage, but there is no problem in actual use.

×: Damage occurred due to multiple use, and there is a problem in actual use.

The evaluation results related to the above evaluation items and the blending ratios of the respective components are shown in Tables 1 and 2 below.

The casings of Examples 1 to 7 were each formed by integrally molding a resin member and a metal member. Therefore, the casings of Examples 1 to 7 are lightweight and excellent in reliability in actual use. On the other hand, the case of the comparative example 1 is composed only of a metal member, and there is a problem in practical use from the viewpoint of weight reduction and miniaturization. The case of the case of the second comparative example is excellent in terms of weight reduction and miniaturization, but it is not reliable from the viewpoint of durability in actual use. The casing of Comparative Example 3 was constructed by a structure in which the resin member and the metal member were not firmly joined. Therefore, although it is excellent in terms of weight reduction and miniaturization, it is lacking in reliability from the viewpoint of durability in practical use.

This application claims to be based on a Japanese patent filed on April 16, 2014. The priority of Japanese Patent Application No. 2014-084337, the entire disclosure of which is hereby incorporated by reference.

1‧‧‧Power conversion device

10‧‧‧shell

12‧‧‧Metal components

14‧‧‧Resin components

Claims (16)

A casing of a power conversion device comprising a resin metal composite body in which a resin member made of a thermosetting resin is adhered to a metal member, and an inner wall surface of the casing of the power conversion device It is composed of the above resin member. The casing of the power conversion device according to claim 1, wherein the resin metal composite has bending fatigue resistance: the above-mentioned metal material having a thickness d ₁ of the resin material and a thickness d ₂ laminated thereon A test piece cut out such that the ratio d ₁ /d ₂ of the material to the thickness of the metal material is 3, and the following first state and the following second state are alternately repeated at a frequency of 30 Hz at a temperature condition of 25 ° C. In the first state, the first state is such that the exposed surface of the resin member is placed on the two support tables without stress, and the second state is: The center of the surface on the member side was applied with a point stress of 140 MPa in the thickness direction to cause the center to sink from the first state. The casing of the power conversion device according to the first aspect of the invention, wherein the test piece obtained by the following treatment for the resin metal composite is allowed to stand at -40 ° C for 1 hour and then at 150 ° C When the heat treatment for one hour is set to one cycle, the above-described heat treatment is performed for 1,000 cycles, and the bending strength of the test piece measured according to JIS K6911 is 200 MPa or more. The above treatment system is to laminate the above-mentioned thickness d ₁ . resin material of the metal material of thickness d ₂ of d than the thickness of the resin material of the metal material ₁ / d ₂ becomes the embodiment 3 was cut out, and calcined for 8 hours at 180 ℃. The casing of the power conversion device according to the first aspect of the invention, wherein the test piece obtained by the following treatment for the resin metal composite is allowed to stand at -40 ° C for 1 hour and then at 150 ° C When the heat treatment for one hour is set to one cycle, after the heat treatment is performed for 1,000 cycles, the bending elastic modulus of the test piece measured according to JIS K6911 is 20 GPa or more; and the above treatment system: the thickness of the laminate is d ₁ the above-described resin material and the thickness d ₂ of the metal material to the resin material and the thickness ratio of the metal material of d ₁ / d ₂ becomes of the embodiment 3 was cut out for 8 hours and calcined at 180 ℃. The casing of the power conversion device according to claim 1, wherein the resin member has a density of 2.5 g/cm ³ or less. The casing of the power conversion device according to the first aspect of the invention, wherein the electromagnetic wave having a frequency of 1 GHz measured by a test piece having a size of 10 cm × 10 cm and a thickness of 4 mm produced by using the resin metal composite is subjected to a KEC method. The shielding effect is above 90dB. The casing of the power conversion device according to the first aspect of the invention, wherein the resin member contains one or more selected from the group consisting of a phenol resin, an epoxy resin, and an unsaturated polyester resin. The casing of the power conversion device according to claim 1, wherein the resin member has a moisture-resistant dielectric breakdown strength of 5 MV/m or more after 1000 hours of moisture resistance treatment at 40 ° C and 90% RH. The casing of the power conversion device of claim 1, wherein the metal member comprises an aluminum or stainless steel material. The casing of the power conversion device of claim 1, wherein the resin metal The composite system is obtained by adhering the metal member described below to the resin member, and the metal member is a measurement angle of 60° measured according to ASTM-D523 of at least the adhesion surface of the resin member. The gloss is 0.1 or more and 30 or less. The casing of the power conversion device according to the first aspect of the invention, wherein the resin metal composite has a plurality of concave portions in a surface of the metal member that is in contact with the resin member, and the cross-sectional shape of the concave portion is as follows Shape: at least a portion of the gap between the opening portion and the bottom portion of the recess portion has a cross-sectional width larger than a cross-sectional width of the opening portion. The casing of the power conversion device according to the first aspect of the invention, wherein the resin metal composite has a plurality of concave portions formed on the adhesion surface of the metal member and the resin member. The layer has a thickness of the roughened layer of 3 μm or more and 40 μm or less. The casing of the power conversion device according to claim 1, wherein the resin metal composite system is formed by adhering the metal member as described below to the resin member, and the metal member is at least the resin The ratio of the actual surface area to the apparent surface area measured by the nitrogen adsorption BET method of the adhesion surface of the member is 100 or more and 400 or less. The casing of the power conversion device of claim 1, wherein the power conversion device is an inverter or a converter. A thermosetting resin composition for forming a resin member of a casing of a power conversion device, the casing of the power conversion device being a resin metal composite obtained by joining the resin member and the metal member The inner wall surface is composed of the above resin member The thermosetting resin composition contains a thermosetting resin. A power conversion device comprising a housing of a power conversion device according to any one of claims 1 to 14.