US20110297549A1 - Aluminum alloy-and-resin composite and method for making the same - Google Patents

Aluminum alloy-and-resin composite and method for making the same Download PDF

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Publication number
US20110297549A1
US20110297549A1 US13/087,500 US201113087500A US2011297549A1 US 20110297549 A1 US20110297549 A1 US 20110297549A1 US 201113087500 A US201113087500 A US 201113087500A US 2011297549 A1 US2011297549 A1 US 2011297549A1
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United States
Prior art keywords
substrate
oxide film
composite
anodic oxide
aluminum alloy
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US13/087,500
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English (en)
Inventor
Wen-Rong Chen
Huann-Wu Chiang
Cheng-Shi Chen
Dai-Yu Sun
Yuan-Yuan Feng
Ke Huang
Chi Lai
Li-Ming Shen
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Hongfujin Precision Industry Shenzhen Co Ltd
Hon Hai Precision Industry Co Ltd
Original Assignee
Hongfujin Precision Industry Shenzhen Co Ltd
Hon Hai Precision Industry Co Ltd
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Assigned to HONG FU JIN PRECISION INDUSTRY (SHENZHEN) CO., LTD., HON HAI PRECISION INDUSTRY CO., LTD. reassignment HONG FU JIN PRECISION INDUSTRY (SHENZHEN) CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHEN, Cheng-shi, CHEN, WEN-RONG, CHIANG, HUANN-WU, FENG, Yuan-yuan, HUANG, KE, LAI, CHI, SHEN, Li-ming, SUN, DAI-YU
Publication of US20110297549A1 publication Critical patent/US20110297549A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
    • C09D167/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
    • C08L81/02—Polythioethers; Polythioether-ethers
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
    • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
    • C23C22/07—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing phosphates
    • C23C22/08—Orthophosphates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
    • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
    • C23C22/46—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing oxalates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C22/82—After-treatment
    • C23C22/83—Chemical after-treatment
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F1/00—Etching metallic material by chemical means
    • C23F1/10—Etching compositions
    • C23F1/14—Aqueous compositions
    • C23F1/32—Alkaline compositions
    • C23F1/36—Alkaline compositions for etching aluminium or alloys thereof
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • C25D11/04—Anodisation of aluminium or alloys based thereon
    • C25D11/16—Pretreatment, e.g. desmutting
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • C25D11/04—Anodisation of aluminium or alloys based thereon
    • C25D11/18—After-treatment, e.g. pore-sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C2045/1486—Details, accessories and auxiliary operations
    • B29C2045/14868—Pretreatment of the insert, e.g. etching, cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B29K2705/02—Aluminium
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/22—Expanded, porous or hollow particles
    • C08K7/24—Expanded, porous or hollow particles inorganic
    • C08K7/28—Glass

Definitions

  • the present disclosure relates to composites of aluminum alloy and resin, particularly to an aluminum alloy-and-resin composite having high bonding strength between aluminum alloy and resin and a method for making the composite.
  • Adhesives for combining heterogeneous materials in the form of a metal (such as light metals) and a synthetic resin are demanded in a wide variety of technical fields and industries, such as the automotive and household appliance fields.
  • adhesives are generally only effective in a narrow temperature range of about ⁇ 50° C. to about 100° C., which means they are not suitable in applications where operating or environmental temperatures may fall outside the range.
  • FIG. 1 is a cross-section view of an exemplary embodiment of a composite of anodized aluminum alloy and resin.
  • FIG. 2 is a scanning electron microscopy view of an exemplary embodiment of the anodized aluminum alloy.
  • FIG. 3 is a scanning electron microscopy cross-section view of the composite shown in FIG. 1 .
  • FIG. 4 is a cross-section view of molding the composite shown in FIG. 1 .
  • FIG. 1 shows an aluminum alloy-and-resin composite 100 according to an exemplary embodiment.
  • the aluminum alloy-and-resin composite 100 includes an aluminum alloy substrate 11 , an anodic oxide film 13 formed on a surface of the aluminum alloy substrate 11 , and resin compositions 15 formed on the anodic oxide film 13 .
  • the anodic oxide film 13 is formed by anodizing the aluminum alloy substrate 11 . Referring to FIG. 2 , the anodic oxide film 13 defines nano-pores 131 . These nano-pores 131 have an average diameter of 30-60 nm. The nano-pores 131 are symmetrically distributed in the anodic oxide film 13 .
  • the resin composition 15 may be coupled to the anodic oxide film 13 by molding. During the molding process, molten resin coats surfaces of the anodic oxide film 13 and fills the nano-pores 131 , thus strongly bonding the resin composition 15 to the anodic oxide film 13 . Compared to the conventional injection molding process using non-anodic film, the composite 100 in this exemplary embodiment has a much stronger bond between the resin composition 15 and the substrate 11 (about quintuple bonding force).
  • the resin composition 15 may be made up of crystalline thermoplastic synthetic resins having high fluidity.
  • polyphenylene sulfide (PPS), polyamide (PA), polyethylene terephthalate (PET), and polybutylene terephthalate (PBT) can be selected as the molding materials for the resin composition 15 , and all of the resins can bond firmly with the anodic oxide film 13 and the substrate 11 .
  • auxiliary components may be added to the resins to modify properties of the composition 15 , for example, fiberglass may be added to PPS.
  • the fiberglass may have a mass percentage of about 10-50%.
  • FIG. 3 shows a scanning electron microscopy cross-sectional view of the composite 100 .
  • FIG. 3 shows a scanning electron microscopy cross-sectional view of the composite 100 .
  • almost no cracks are observed between the resin composition 15 and the anodic oxide film 13 , clearly demonstrating that the resin composition 15 tightly bonds to the anodic oxide film 13 and fills the nano-pores 131 .
  • a method for making the composite 100 may include the following steps:
  • the aluminum alloy substrate 11 is provided.
  • the substrate 11 is degreased.
  • the degreasing process may include the step of dipping the substrate 11 in a sodium salt solution for about 5-15 minutes.
  • the sodium salt solution may include sodium carbonate having a concentration of about 30-50 grams per liter (g/L), sodium phosphate having a concentration of about 30-50 g/L, and sodium silicate having a concentration of about 3-5 g/L.
  • the temperature of the sodium salt solution may be about 50-60° C.
  • the surface of the substrate 11 is roughened.
  • Roughening the substrate 11 may include the step of chemically etching.
  • the chemical etching process may include the step of dipping the substrate 11 in an alkaline solution for about 1-2 minutes.
  • the alkaline solution may include sodium hydroxide having a concentration of about 20-35 g/L, and sodium carbonate having a concentration of about 20-30 g/L.
  • the temperature of the alkaline solution may be about 40-55° C.
  • the chemical etching process roughens the surface of the substrate 11 so that it will be more uniformly anodized and to obtain a narrower range of diameters of the nano-pores 131 of the anodic oxide film 13 .
  • the substrate 11 is removed from the alkaline solution and rinsed in water.
  • the substrate 11 is anodized to form the anodic oxide film 13 .
  • the anodizing process may be carried out in a sulfuric acid solution, with the substrate 11 being an anode, and a stainless steel board or a lead plate being a cathode.
  • the sulfuric acid solution may have a concentration of about 100-250 ml/L.
  • the electric current density through the sulfuric acid solution is about 0.5-4.9 A/dm 2 .
  • Anodizing the substrate 11 may last for about 15-60 minutes. Then, the substrate 11 is rinsed in water and then dried.
  • anodizing process can also be carried out in a phosphoric acid solution or an oxalic acid solution.
  • an injection mold 20 is provided.
  • the injection mold 20 includes a core insert 23 and a cavity insert 21 .
  • the core insert 23 defines several gates 231 , and several first cavities 233 .
  • the cavity insert 21 defines a second cavity 211 for receiving the substrate 11 .
  • the anodized substrate 11 is located in the second cavity 211 , and molten resin is injected through the gates 231 to coat the surface of the anodic oxide film 13 and fill the nano-pores 131 , and finally fill the first cavities 233 to form the resin compositions 15 , as such, the composite 100 is formed.
  • the molten resin may be crystalline thermoplastic synthetic resins having high fluidity, such as PPS, PA, PET, and PBT.
  • the injection mold may be at a temperature of about 120-170° C.
  • Tensile strength and shear strength of the composite 100 have been tested. The tests indicate that the tensile strength of the composite 100 is greater than 8 MPa, and the shear strength of the composite 100 is greater than 15 MPa. Furthermore, the composite 100 has been subjected to a temperature humidity bias test (72 hours, 85° C., relative humidity: 85%) and a thermal shock test (48 hours, ⁇ 40-85° C., 4 hours/cycle, 12 cycles total), such testing did not result in decreased tensile strength and shear strength of the composite 100 .
  • a temperature humidity bias test 72 hours, 85° C., relative humidity: 85%
  • a thermal shock test 48 hours, ⁇ 40-85° C., 4 hours/cycle, 12 cycles total
US13/087,500 2010-06-04 2011-04-15 Aluminum alloy-and-resin composite and method for making the same Abandoned US20110297549A1 (en)

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CN201010192062.9 2010-06-04
CN2010101920629A CN102268183A (zh) 2010-06-04 2010-06-04 铝或铝合金与塑料的复合体及其制作方法

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US20140360974A1 (en) * 2012-02-24 2014-12-11 Shenzhen Byd Auto R&D Company Limited Method of preparing aluminum alloy resin composite and aluminum alloy-resin composite obtainable by the same
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