TW201825220A - 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

   Laser scanning method   

The present invention relates to a method for producing a composite molded article including a metal molded article and a resin molded article.

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

However, a technology capable of joining a metal formed body and a resin formed body in an industrially advantageous method with high bonding strength has not yet been put into practical use.

Japanese Patent No. 4020957 describes an invention of a laser processing method for a metal surface bonded to a different material (resin), which includes the steps of performing laser scanning on a metal surface in a scanning direction; and Steps of laser scanning in the cross scanning direction.

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

However, the inventions of Japanese Patent No. 4020957 and Japanese Patent Application Laid-Open No. 2010-167475 must perform laser scanning in two directions crossing each other, so there is still room for improvement in terms of consuming excessive processing time.

Furthermore, it is considered that the laser scanning in the cross direction can perform sufficient surface roughening treatment, so that the joint strength can be improved, but there are problems such as uneven surface roughness and the strength of the joint between metal and resin. Orientation may be unstable.

For example, one joint has the highest shear or tensile strength in the X-axis direction, but the other joint has the highest shear or tensile strength in the Y-axis direction, which is different from the X-axis direction. In addition, another problem that the shear force or tensile strength in the Z-axis direction which is different from the X-axis and Y-axis directions is the highest may occur.

Although depending on the product (such as a rotating body part in one direction or a reciprocating part in the-direction), there may be a case where a metal and resin composite body having high joint strength in a specific direction is required. However, Japanese Patent No. 4020957, Japan, The invention of Japanese Patent Application Laid-Open No. 2010-167475 cannot sufficiently meet the aforementioned requirements.

In addition, in the case where the joint surface has a complex shape or a shape including a thinner width portion (for example, a star shape, a triangle shape, or a dumbbell shape), it is considered that the method of performing laser scanning along the crossing direction may roughen a part of the surface. It becomes uneven, and as a result, sufficient bonding strength cannot be obtained.

Japanese Patent Application Laid-Open No. 10-294024 discloses a method for manufacturing electrical and electronic parts in which irregularities are formed by irradiating a metal surface with laser light, and molding resin, rubber, and the like are projected at the irregularity forming portions.

In Embodiments 1 to 3, it is described that the surface of the metal long-sized coil is irradiated with laser light to form irregularities. In paragraph number 10, the surface of the long metal coil is roughened into a stripe or satin pattern. In paragraph number 19, the surface of the long metal coil is roughened into a stripe, a dotted line, a wavy line, and a knurl. Shape, satin-like.

However, as described in the effects of the inventions of paragraphs 21 and 22, the purpose of laser irradiation is to form fine and irregular irregularities on the metal surface, thereby improving the alignment effect. In particular, since the object to be processed is a long metal coil, it is considered that no matter what kind of unevenness is formed, fine and irregular unevenness is necessarily formed.

Therefore, the invention of Japanese Patent Application Laid-Open No. 10-294024 discloses that, as in the inventions of Japanese Patent No. 4020957 and Japanese Patent Laid-Open No. 2010-167475, the surface of the surface is formed with fine projections and depressions by laser irradiation in a cross direction. Invent the same technical idea.

International Publication No. 2012/090671 is an invention of a method for manufacturing a composite molded body including a metal molded body and a resin molded body. It has the step of performing laser scanning on the joining surface of the metal formed body in such a way that marks including straight lines and / or curves are formed in the-direction or different directions, and it is based on the marks including each straight line and / or each curve. Laser scanning steps are performed in an uncrossed manner. Figures 6 to 9 show square, circular, oval, and triangular marking patterns.

The present invention has as its object to provide a method for manufacturing a composite formed body which can further improve the bonding strength.

As a solution to the problem, the present invention provides a method for manufacturing a composite molded body, which is a method for manufacturing a composite molded body in which a metal molded body and a resin molded body are joined, which includes a first step for the aforementioned metal The joint surface of the formed body is irradiated with laser light having a laser spot diameter in the range of 10 to 200 μm to form a groove, and a step of forming a circle having a diameter of 20 to 1000 μm or an area in the same area as the same is used to connect the laser by one scan Forming a groove by starting and ending the irradiation, and repeating multiple scans to form an area surrounded by the groove; in a second step, repeating the aforementioned first step to form a plurality of areas surrounded by the groove; and In the third step, a portion including a metal-molded body joint surface in which a region surrounded by the groove is formed is placed in a mold, and a resin to be the resin-molded body is insert-molded.

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

1‧‧‧ composite formed body

10‧‧‧ metal forming body

12‧‧‧ joint surface

20‧‧‧Resin molding

FIG. 1 is a cross-sectional view (including a partially enlarged view) of the composite formed body obtained by the manufacturing method of the present invention in the thickness direction.

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

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

Figures 4 (a) to (g) are diagrams showing the formation pattern of the area surrounded by the texture in the manufacturing method of the present invention.

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

(A) of FIG. 6 is an SEM photograph of a top view of a metal formed body used in the composite formed body of Example 1. (b) of FIG. 6 is an enlarged view of (a) of FIG. 6; c) It is a SEM photograph of the thickness direction cross section of FIG.6 (a).

FIG. 7 is an explanatory diagram of a manufacturing method of Comparative Example 1. FIG.

FIG. 8 is a diagram for explaining a method for measuring the joint strength of the composite formed bodies of Examples and Comparative Examples.

    [Form of Implementing Invention]    

FIG. 1 is a cross-sectional view (including a partially enlarged view) in the thickness direction of a composite molded body 1 in which a flat metal molded body 10 and a flat resin molded body 20 are integrated with each other in a plane.

FIG. 2 (a) is a cross-sectional view in the thickness (diameter) direction of the composite molded body 1 in which a cylindrical (round bar) metal molded body 10 and a cylindrical resin molded body 20 are integrated with each other by curved surfaces.

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

<Step 1>

As shown in the top view and a partially enlarged view in FIG. 3, in the first step, the joint surface of the metal formed body 10 before the integration is irradiated with a laser spot diameter (d) in a range of 10 to 200 μm. The laser light forms the groove 31 to form a circle having a diameter (D) of 20 to 1000 μm or an area within the same area range.

Furthermore, in the first step, the groove 31 is formed by connecting the starting point and the end point of the laser irradiation with one scan, and repeating a plurality of scans to form the same groove 31 to form the groove 31 An area surrounded.

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

The groove 31 is formed by connecting the start point and the end point of the laser irradiation with one scan, as shown in a partially enlarged view in FIG. 3. That is, laser irradiation is performed so that laser points adjacent to each other 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 in the same manner as the first scan. The depth of the groove 31 (that is, the height of the convex portion 32) is adjusted by performing multiple scans.

In the first step, the area 30 surrounded by the groove 31 can be made from a pentagon or more, in addition to the circles, ellipses, triangles, and quadrilaterals shown in Figs. 4 (a) to (g). Polygonal and irregularly shaped regions may also be regions containing other shapes.

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

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

The size of a region is a circle with a diameter (D) of 20 to 1000 μm or the same area range, preferably a circle with a diameter (D) of 20 to 500 μm or a range with 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 100 to 100,000 μm, more preferably 100 to 10,000 μm, and even more preferably 100 to 1000 μm. In this way, by shortening the irradiation distance for one scan, it is possible to suppress the diffusion of heat between the scans and the decrease in the metal temperature. Therefore, the efficiency of laser processing (the amount of processing per unit time) becomes good.

The groove depth formed by the laser light irradiation in one scan is preferably 5 to 300 μm, and more preferably 10 to 300 μm.

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

The irradiation conditions of the laser light at 30 when forming such a groove-containing area are as follows:

The output power is preferably 4 ~ 4000W.

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

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

The frequency is preferably 1 to 100 kHz.

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

The processing speed is preferably 10 to 10,000 mm / sec, more preferably 100 to 10,000 mm / sec, and even more preferably 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 to form a plurality of regions 30 (30a to 30g) as shown in Figs. 4 (a) to (g) on the joint surface 12 of the metal formed body 10.

In Figs. 4 (a) to (e), a region 30 (30a to 30e) is formed on the entire surface of the joint surface 12. Figs. 4 (f) and (g) are regions formed on the -part surface 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 independent and not in contact with each other, but the grooves 31a of all or a part of the regions 30a may overlap 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 independent and not in contact with each other, but the grooves 31b of all or a part of the regions 30b may overlap 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 independent and not in contact with each other, but the grooves 31c of all or a part of the regions 30c may overlap 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 independent and not in contact with each other, but the grooves 31d of all or a part of the regions 30d may overlap each other.

In FIG. 4 (e), the arrangement state is different from that in FIG. 4 (a), and 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 independent and not in contact with each other, but the grooves 31e of all or a part of the regions 30e may overlap each other.

Fig. 4 (f) is different from Figs. 4 (a) and (e) in that a plurality of circular regions 30f having grooves 31f and convex portions 32f are formed on a part 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 part of the regions 30f may overlap each other.

In FIG. 4 (f), the plurality of circular regions 30f are formed such that the formation density of the circular regions 30f on the side 12a side of the joint surface 12 is increased, and the circular regions 30f on the opposite side 12b side are formed. It is formed so that the formation density becomes low. As described above, the circular areas 30f are not uniformly arranged on the joint surface 12 and can be preformed so as to be biased to the -part surface.

When the composite molded body 1 shown in FIG. 1 is formed with a plurality of circular areas 30f shown in FIG. 4 (f) on the joint surface 12, the circular areas 30f are formed densely on the side 12a. Therefore, the composite molded body 1 has a higher resistance when it is stretched in the direction of the arrow in FIG. 4 (f), and the bonding strength between the metal molded body 10 and the resin molded body 20 can be improved.

In Fig. 4 (g), different from Figs. 4 (a) and (e), a plurality of circular areas 30g having grooves 31g and convex portions 32g are formed around the joint surface 12, and are not formed in the central portion. Round 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 overlap each other.

In addition, contrary to FIG. 4 (g), a plurality of circular regions 30g may be formed only in the center portion of the joint surface 12, and no circular regions 30g may be formed around the periphery.

<Step 3>

In the third step, a part 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 insert molding is performed using a resin that becomes the resin formed body 20 to obtain a composite formed body 1.

As a result of the insert molding step, as shown in FIG. 1, a composite molded body 1 in a state where resin is infiltrated into the grooves 31 in the region 30 (the grooves 31 and the protrusions 32) is obtained.

In this way, since the metal formed body 10 has a region 30 (the groove 31 and the protrusion 32), the contact area between the metal formed body 10 and the resin formed body 20 can be increased, and the alignment generated by filling the groove 31 with the resin can also be achieved. Effect to increase the bonding strength.

Furthermore, for example, as shown in Figs. 4 (a) to (g), by adjusting the arrangement state of the area 30 or adjusting the formation pattern, a composite molding having improved tensile strength or bending strength in a desired direction can be obtained. body.

The metal of the metal formed body used in the composite formed body of the present invention is not particularly limited, and can be appropriately selected from known metals depending on the application. Examples thereof include those selected from iron, various stainless steels, aluminum or alloys thereof, copper or alloys thereof, silver or alloys thereof, zinc, magnesium, lead, tin, and alloys containing them.

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

The resin of the resin molded article 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 application. Examples include polyamine resins (aliphatic polyamines such as PA6 and PA66, aromatic polyamines), polystyrene, ABS resin, AS resins, copolymers containing styrene units, polyethylene, and ethylene units. Copolymers, polypropylene, copolymers containing propylene units, other polyolefins, polyvinyl chloride, polyvinylidene chloride, polycarbonate resins, acrylic resins, methacrylic resins, polyester resins, Polyacetal resin, polyphenylsulfide resin.

The thermosetting resin can be appropriately selected from known thermosetting resins depending on the application. Examples include urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin, polyurethane, and vinyl carbamate.

The thermoplastic elastomer can be appropriately selected from known thermoplastic elastomers depending on the application. Examples thereof include a styrene-based elastomer, a vinyl chloride-based elastomer, an olefin-based elastomer, a urethane-based elastomer, a polyester-based elastomer, a nitrile-based elastomer, and a polyamide-based elastomer.

These thermoplastic resins, thermosetting resins, and thermoplastic elastomers may be blended with a known fibrous filler.

Examples of known fibrous fillers include carbon fibers, inorganic fibers, metal fibers, and organic fibers.

The carbon fiber is well-known, and PAN-based, pitch-based, sacral-based, wood-based fibers can be used.

Examples of the inorganic fibers include glass fibers, basalt fibers, silica fibers, silica and alumina fibers, zirconia fibers, boron nitride fibers, and silicon nitride fibers.

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

As the organic fibers, polyamide fibers (fully aromatic polyamide fibers, semi-aromatic polyamide fibers in which any one of diamine and dicarboxylic acid is an aromatic compound, and aliphatic polyamide fibers), Polyvinyl alcohol fiber, acrylic fiber, polyolefin fiber, polyoxymethylene fiber, polytetrafluoroethylene fiber, polyester fiber (including wholly aromatic polyester fiber), polyphenylene sulfide fiber, polyimide fiber, liquid crystal polyester fiber Such as synthetic fibers, natural fibers (cellulose-based fibers, etc.) or regenerated cellulose (嫘 萦) fibers.

These fibrous fillers may be those having a fiber diameter in the range of 3 to 60 μm. However, among these, it is preferable to use, for example, a fiber diameter smaller than the width of the marking pattern (fine The size of the opening of the hole, or the width of the groove). The fiber diameter is more preferably 5 to 30 μm, and even more preferably 7 to 20 μm.

When such a fibrous filler having a fiber diameter smaller than the width of the mark pattern is used, a composite molded body can be obtained in which a part of the fibrous filler is stuck in the mark pattern of the metal molded body, and the metal molded body and the resin can be molded. The joint strength of the body is better.

Furthermore, since these fibrous fillers improve the bonding strength between the metal molded body and the resin molded body by increasing the mechanical strength of the resin molded body and reducing the difference in mechanical strength with the metal molded body, it is preferred that the fibrous filler is formed by molding. The weight average fiber length contained in the following resin formed body can be formed to a length of preferably 0.1 to 5.0 mm, more preferably 0.1 to 4.0 mm, still more preferably 0.2 to 3.0 mm, and most preferably 0.5 to 2.5 mm. Used as a manufacturing material.

The blending amount of the fibrous filler of the thermoplastic resin, the thermosetting resin, and the thermoplastic elastomer is preferably 5 to 250 parts by mass based on 100 parts by mass. It is more preferably 25 to 200 parts by mass, and even more preferably 45 to 150 parts by mass.

A well-known laser can be used in the method for manufacturing the composite molded body of the present invention, and for example, YVO ₄ laser, YAG laser, fiber laser, excimer laser, ultraviolet laser, carbon dioxide laser, semiconductor laser, Glass laser, ruby laser, He-Ne laser, nitrogen laser, chelate laser, pigment laser.

Laser irradiation conditions, such as wavelength, beam diameter, pore interval, and number of cycles, can be appropriately determined according to the size, quality, type, or required bonding strength of the metal molded and resin molded objects to be joined. Decide.

    [Example]    

Example 1

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

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

After forming a circular area in the metal formed body in the above manner, insert molding was performed in the following manner to obtain the composite formed body of Example 1.

Comparative Example 1

The joint surface 12 of the metal formed body (aluminum: A5052) shown in FIG. 5 was subjected to laser irradiation under the conditions shown in Table 1 to form a groove including a straight line that was bent several times in the state shown in FIG. The laser oscillator is a fiber laser (YLP-1-50-30-30RA, manufactured by IPG).

After forming grooves including straight lines in the metal formed body in the above manner, insert molding was performed in the following manner to obtain a composite formed body of Comparative Example 1.

Comparative Example 2

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

After forming grooves including straight lines in the metal formed body in the manner described above, insert molding was performed by the following method to obtain a composite formed body of Comparative Example 2.

<Inset molding (injection molding)>

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

Resin temperature: 320 ℃

Mold temperature: 100 ℃

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

    [Stretching test]    

The composite formed bodies of Example 1 and Comparative Examples 1 and 2 were used to perform a tensile test and evaluate the joint strength (S1). The results are shown in Table 1.

The fiber length (weight-average fiber length) of glass fibers in the resin molded body of the composite molded body was 0.85 mm. About 3g of the average fiber length was cut from the molded product, heated at 650 ° C, ashed, and taken out of the glass fiber. The weight-average fiber length was calculated from a part (500) of the fibers taken out. The calculation formula used [0044] and [0045] of Japanese Patent Application Laid-Open No. 2006-274061.

The tensile test measures the maximum load when the metal molded body is fixed in the state of being stretched in the direction X1 shown in FIG. 8 until the metal molded body and the resin molded body are broken.

<Tensile test conditions>

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

Stretching speed: 5mm / min

Distance between chucks: 50mm

Compared with Comparative Examples 1 and 2, since the irradiation distance of one scan is shorter in Example 1, the diffusion of heat can be suppressed, and therefore, the groove depth of each scan can be increased.

Therefore, if Example 1 and Comparative Example 1 are compared, Example 1 can shorten the total scanning time, and it can be confirmed that a composite molded body having higher bonding strength than Comparative Example 1 can be obtained.

In addition, when Example 1 and Comparative Example 2 were compared, it was confirmed that a composite molded article having a bonding strength three times or more was obtained at the same total scanning time.

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 (10)

    A laser scanning method includes: a first step of forming grooves by irradiating laser light having a laser spot diameter in a range of 10 to 200 μm on a joint surface of a metal forming body to form a circular or The step of forming an area in the same area as the area, forming a groove by connecting the starting point and the end point of the laser irradiation with one scan, and repeating the plurality of scans to form an area surrounded by the groove; and the second step Then, the first step is repeated to form a plurality of regions surrounded by the trench.         For example, the laser scanning method of claim 1, wherein the irradiation distance of one scan is 100-100,000 μm.         For example, the laser scanning method of item 1 or 2, wherein the processing speed of the laser light is 10 to 10,000 mm / sec.         The laser scanning method according to claim 1 or 2, wherein in the first step, an area surrounded by the groove is selected from the group consisting of a circle, an oval, a triangle, a quadrangle, a pentagon and a polygon formed by the groove, and Irregularly shaped area.         The laser scanning method according to claim 1 or 2, wherein the second step is a step of forming a plurality of independent regions.         For example, the laser scanning method according to claim 1 or 2, wherein the second step is a step of forming all or a part of areas adjacent to each other to overlap each other.         The laser scanning method 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 laser scanning method according to claim 1 or 2, wherein the second step is a step of forming a plurality of regions on a part of a joint surface of the metal formed body.         The laser scanning method according to claim 1 or 2, wherein the joining surface of the metal formed body is a flat surface or a curved surface.         The laser scanning method according to claim 1 or 2, wherein the joint surface of the metal formed body is a joint surface that is joined to the resin formed body.