WO2013047365A1 - アルミ樹脂接合体及びその製造方法 - Google Patents
アルミ樹脂接合体及びその製造方法 Download PDFInfo
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- WO2013047365A1 WO2013047365A1 PCT/JP2012/074216 JP2012074216W WO2013047365A1 WO 2013047365 A1 WO2013047365 A1 WO 2013047365A1 JP 2012074216 W JP2012074216 W JP 2012074216W WO 2013047365 A1 WO2013047365 A1 WO 2013047365A1
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- WIPO (PCT)
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- resin
- aluminum
- oxygen
- zinc
- film
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8207—Testing the joint by mechanical methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8207—Testing the joint by mechanical methods
- B29C65/8215—Tensile tests
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8207—Testing the joint by mechanical methods
- B29C65/8246—Pressure tests, e.g. hydrostatic pressure tests
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8253—Testing the joint by the use of waves or particle radiation, e.g. visual examination, scanning electron microscopy, or X-rays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
- B29C65/8261—Testing the joint by the use of thermal means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/026—Chemical pre-treatments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7422—Aluminium or alloys of aluminium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- 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
- C23C22/68—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 solutions with pH between 6 and 8
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/73—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 characterised by the process
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/78—Pretreatment of the material to be coated
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/31507—Of polycarbonate
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
Definitions
- the present invention relates to an aluminum resin joined body in which an aluminum base material made of aluminum or an aluminum alloy and a resin molded body made of a thermoplastic resin are integrally and firmly joined by injection molding or thermocompression bonding of a thermoplastic resin, and its It relates to a manufacturing method.
- the present inventors have already made an aluminum / resin injection integrated molded product in which an aluminum shaped body and a resin molded body are already locked together by a concave portion of an aluminum material and a fitting portion of a thermoplastic resin.
- Patent Document 1 an aluminum alloy member excellent in resin bondability characterized by having a convex portion made of silicon crystal
- Patent Document 2 an aluminum alloy member excellent in resin bondability characterized by having a convex portion made of silicon crystal
- a technique for integrating an aluminum alloy material and a thermoplastic resin composition obtained through a pretreatment immersed in one or more aqueous solutions selected from ammonia, hydrazine, and a water-soluble amine compound by injection molding (Patent Documents 3 and 4), an aqueous solution of triazine dithiols, or a solution using various organic solvents as a solvent is used as an electrodeposition solution, and after the electrochemical surface treatment of the metal, the metal after the surface treatment (Patent Document 5) that joins rubber and plastic has been proposed. Further, an adhesive is applied on a metal plate, or an organic film is formed by surface treatment, and then injection molding is performed.
- Technology for integrating metal and resin (Patent Document 6), or treating the surface of the metal with an acid or alkali and then treating with a silane coupling agent, followed by injection molding Techniques for joining the (Patent Document 7) have been proposed respectively.
- Patent Document 1 and Patent Document 2 the present inventors have so far proposed a physical bonding mainly based on the fitting of the anchor effect, and a special treatment in which halogen ions are contained in the treatment bath as the technique.
- a method by a simple etching process has been proposed. Although these methods have no problem in performance such as bonding strength and airtightness of the bonded portion, gas derived from halogen is generated during this etching process, and the surrounding metal parts and equipment are not corroded. There was another issue of having to take measures to prevent polluting the environment.
- the present inventors have no problem with surrounding equipment and environment when joining the aluminum base and the resin molded body made of thermoplastic resin, are easy operation, low cost, and long-term.
- an oxygen-containing film containing oxygen is formed on the surface of the aluminum base material, and a thermoplastic resin is formed on the oxygen-containing film.
- thermoplastic resin having an element having an unshared electron pair in the repeating unit and / or terminal is used as the thermoplastic resin, so that the aluminum base and the resin molded body are
- injection molding or thermocompression bonding aluminum-resin bonding
- an object of the present invention is to provide an aluminum resin joint that exhibits excellent bonding strength between aluminum and resin, and that does not cause a decrease in strength after a durability test and can maintain excellent bonding strength between aluminum and resin over a long period of time. To provide a body.
- the present invention relates to an aluminum substrate made of aluminum or an aluminum alloy, an oxygen-containing film containing oxygen formed on the surface of the aluminum substrate, and a thermoplastic resin bonded on the oxygen-containing film.
- a formed resin molded body, The aluminum resin bonded body is characterized in that the thermoplastic resin is a thermoplastic resin having an element having an unshared electron pair in a repeating unit and / or at a terminal.
- the present invention also provides a film forming step for forming an oxygen-containing film on the surface of an aluminum substrate made of aluminum or an aluminum alloy, and an oxygen-containing film on the surface-treated aluminum substrate obtained in the film forming step.
- a resin molding step of forming a resin molded body by injection molding of a thermoplastic resin, and producing an aluminum resin joined body in which an aluminum base material and a resin molded body are joined via the oxygen-containing film It is a manufacturing method of a joined body,
- the thermoplastic resin is a thermoplastic resin having an element having an unshared electron pair in a repeating unit and / or at a terminal.
- the present invention provides a film forming process for forming an oxygen-containing film on the surface of an aluminum substrate made of aluminum or an aluminum alloy, a resin molding process for forming a resin molded body by injection molding of a thermoplastic resin, and the film formation.
- thermoplastic resin is a thermoplastic resin having an element having an unshared electron pair in a repeating unit and / or at a terminal.
- the material, shape, etc. of the aluminum base material used as the substrate is not particularly limited as long as it is made of aluminum or an aluminum alloy, and the use of the aluminum resin joined body formed using this or the use thereof Can be determined on the basis of various physical properties such as strength, corrosion resistance, and workability required.
- the oxygen-containing film formed on the surface of such an aluminum base material in the film forming step is not particularly limited as long as the adhesion to the aluminum base material is good, but preferably zinc ions Al (OH) 3 , AlO (OH), which is a film containing zinc element obtained by a zinc-containing film formation process using an aqueous alkaline solution, or derived from an aluminum film formation process performed wet and electrolessly Any one selected from the group consisting of Al 2 O 3 , Al (PO 4 ), Al 2 (HPO 4 ) 3 , Al (H 2 PO 4 ) 3 , and Al (H 2 PO 4 ) 3
- the film may be any film selected from films containing two or more types of aluminum compounds, or may be a film formed on the surface of an aluminum substrate by laser treatment.
- zinc oxide (ZnO) and zinc oxide together with zinc element are formed on the surface of the aluminum base material.
- the film containing iron (ZnFeO), zinc oxide aluminum (ZnAlO), etc. can be formed, and the thermoplastic resin has an element having a lone pair, injection molding of this thermoplastic resin
- the resin molded body is molded by, or by thermocompression bonding with the resin molded body obtained by molding the thermoplastic resin, the resin molded body formed on the oxygen-containing film is firmly Bonding strength between aluminum and resin is achieved.
- the zinc-containing film-forming process using the zinc ion containing aqueous alkali solution preferably, alkali hydroxide (MOH) and zinc ion (Zn 2+) in a weight ratio (MOH / Zn 2+) 1 or more to 100 or less
- a zinc ion-containing alkaline aqueous solution containing a ratio of 2 to 20, preferably 2 to 20 and more preferably 3 to 10 and contacting the zinc ion-containing alkaline aqueous solution with the surface of the aluminum substrate at room temperature.
- a zinc-containing film containing oxygen is preferably formed on the surface of the aluminum substrate.
- the alkali source in the zinc ion-containing alkaline aqueous solution preferably one or more selected from sodium hydroxide, potassium hydroxide, and lithium hydroxide is used, and this zinc ion-containing alkaline aqueous solution is used.
- the zinc ion source is preferably at least one selected from zinc oxide, zinc hydroxide, zinc peroxide, zinc chloride, zinc sulfate, and zinc nitrate.
- the alkali hydroxide concentration is 10 g / L or more and 1000 g / L or less, preferably 50 g / L or more and 300 g / L or less. It may be 1 g / L or more and 200 g / L or less, preferably 10 g / L or more and 100 g / L or less.
- membrane on the surface of an aluminum base material for example, the aluminum base material which consists of aluminum or an aluminum alloy is 60 seconds in 50 degreeC or more warm water.
- An oxygen-containing film containing one or more aluminum compounds selected from 3 , Al (H 2 PO 4 ) 3 , and AlOSiO 2 is formed.
- these hot water immersion treatment, water vapor treatment, and phosphoric acid treatment may be performed by any one of them to form an oxygen-containing film on the surface of the aluminum base material.
- These two types of treatments may be combined to form a necessary oxygen-containing film on the surface of the aluminum substrate.
- the aluminum base is melted in the vicinity of the surface of the aluminum base, preferably only in the vicinity of the surface. It suffices to heat and oxidize to above the temperature and deposit an aluminum oxide (Al 2 O 3 ) near the surface of the aluminum substrate to form an oxygen-containing film containing this aluminum oxide (Al 2 O 3 ). For example, it can be performed using a laser etching apparatus or the like.
- the surface-treated aluminum base material obtained by forming an oxygen-containing film on the surface of an aluminum base material by the said film formation process measures by EPMA in the surface layer from the outermost surface to the depth of 3 micrometers.
- the amount of oxygen is 0.1% by weight to 48% by weight, preferably 0.5% by weight to 20% by weight, and more preferably 1% by weight to 10% by weight. If the amount of oxygen in the surface layer of this surface-treated aluminum base material is lower than 0.1% by weight, it may be difficult to achieve sufficient aluminum-resin bonding strength between the aluminum and the resin. In addition, it is difficult to make the oxygen amount higher than 48% by weight.
- the resin molded body is integrally bonded onto the oxygen-containing film by injection molding of a thermoplastic resin.
- thermoplastic resin used in the above resin molding step a thermoplastic resin having an element having an unshared electron pair in the repeating unit and / or the terminal is used.
- the element having an unshared electron pair that the thermoplastic resin has is preferably one or more selected from sulfur, oxygen, and nitrogen.
- the element which has these unshared electron pairs contained in the repeating unit of a thermoplastic resin it may be contained in the principal chain of a repeating unit, or may be contained in the side chain.
- thermoplastic resin having an element having an unshared electron pair in the repeating unit and / or terminal specifically, a resin containing a sulfur element such as polyphenylene sulfide (PPS) or a sulfone-based resin
- a resin containing a sulfur element such as polyphenylene sulfide (PPS) or a sulfone-based resin
- polyester resins such as polybutylene terephthalate (PBT), resins containing oxygen atoms such as liquid crystal polymers, polycarbonate resins, polyacetal resins, polyether resins, polyphenylene ether resins, such as polyamide (PA), ABS , Thermoplastic resins containing nitrogen atoms such as polyimide and polyetherimide.
- thermoplastic resin for producing a resin molded body bonded to the surface of the aluminum base material having the oxygen-containing film described above is derived from a carbonyl group (C ⁇ O) in IR analysis. It is a thermoplastic resin in which a resin molded body having a peak (near 1730 cm ⁇ 1 ) is molded.
- an oxygen-containing film is formed on the entire surface of the aluminum base material to be a base, and resin molding is performed by injection molding only at a necessary portion of the obtained surface-treated aluminum base material or by thermocompression bonding.
- the body may be joined, or in consideration of cost, an oxygen-containing film is formed only on a part of the surface of the aluminum base material or at a necessary portion, and the obtained surface-treated aluminum base material is necessary.
- the resin molded body may be joined to the location by injection molding or thermocompression bonding.
- the oxygen-containing film is formed after masking portions other than the part that forms the oxygen-containing film, for example, with a masking tape or the like.
- a process for forming the mask may be performed, and then the masking tape or the like of the masked portion may be removed.
- the method for producing an aluminum resin joined body according to the present invention as necessary, prior to the film formation step for forming the oxygen-containing film, as a pretreatment of the surface of the aluminum substrate, degreasing treatment, etching treatment, desmut treatment, chemical polishing Any one or more treatments selected from a treatment and an electrolytic polishing treatment may be performed.
- the degreasing process performed as said pre-processing it can carry out using the normal degreasing bath which consists of sodium hydroxide, sodium carbonate, sodium phosphate, surfactant, etc.
- immersion temperature is usually 15
- the immersion time is 1 minute or more and 10 minutes or less, preferably 3 minutes or more and 6 minutes or less.
- an alkali aqueous solution such as sodium hydroxide or an acid aqueous solution such as a sulfuric acid-phosphoric acid mixed aqueous solution is usually used.
- concentration of 20 g / L or more and 200 g / L or less is used, Preferably it is 50 g / L or more and 150 g / L or less, Immersion temperature 30 to 70 degreeC, Preferably it is 40 to 60 degreeC.
- the immersion treatment may be performed under a treatment condition of not more than ° C. and a treatment time of 0.5 to 5 minutes, preferably 1 to 3 minutes.
- the sulfuric acid concentration is 10 g / L or more and 500 g / L or less, preferably 30 g / L or more and 300 g / L or less
- the phosphoric acid concentration is 10 g / L or more and 1200 g. / L or less, preferably 30 g / L or more and 500 g / L, immersion temperature 30 ° C. or more and 110 ° C. or less, preferably 55 ° C. or more and 75 ° C. or less, and immersion time 0.5 minutes or more and 15 minutes or less, preferably
- the immersion treatment is preferably performed under a treatment condition of 1 minute or more and 6 minutes or less.
- a desmut bath made of an aqueous nitric acid solution having a concentration of 1 to 30% is used, an immersion temperature of 15 ° C. to 55 ° C., preferably 25 ° C. to 40 ° C., and an immersion time of 1
- the immersion treatment may be performed under a treatment condition of not less than 10 minutes and not more than 10 minutes, preferably not less than 3 minutes and not more than 6 minutes.
- a conventionally well-known method is employable about the chemical polishing process and electropolishing process performed as said pre-processing.
- the surface-treated aluminum base material is exposed for 24 hours to obtain a stearic acid-treated aluminum base material having a monomolecular film of stearic acid on the oxygen-containing film, and carbonyl groups (
- Stearic acid has both a carboxyl group (COOH) which is a hydrophilic group and an alkyl group (C 17 H 35 ) which is a hydrophobic group, and has a property of forming a monomolecular film having a thickness of one molecule.
- COOH carboxyl group
- C 17 H 35 alkyl group
- Stearic acid-treated aluminum PPS joined body the oxygen-containing film of the aluminum base and the carboxyl group side of stearic acid are chemically bonded, and the alkyl group side comes into contact with the PPS molded product. It is thought that the chemical bond between the base material and the PPS compact was hindered, and the joint strength was lower than the joint strength of the aluminum PPS joint.
- the surface-treated aluminum base material before and after the stearic acid treatment was compared and examined by observing the surface, but no difference was found in the surface structure depending on the presence or absence of the stearic acid monomolecular film.
- the contact angle was close to 180 °, and the droplet was almost spherical. This is a result of supporting that the alkyl group side of stearic acid is unevenly distributed on the outermost layer side of the aluminum base material.
- the aluminum resin joined body of the present invention is obtained by coating the surface of an aluminum substrate with an oxygen-containing film, and then using a thermoplastic resin containing an element having an unshared electron pair, by injection molding of this thermoplastic resin, or
- the resin molded body obtained by injection molding of this thermoplastic resin is obtained by joining the resin molded body on the oxygen-containing film on the surface of the aluminum base material by thermocompression bonding.
- the aluminum base material and the resin molded body are not only firmly bonded, but also excellent aluminum-resin bonding strength can be maintained over a long period of time.
- an aluminum resin joined body of the present invention in the film forming process for forming the oxygen-containing film on the surface of the aluminum base material, there is no gas generation and the operation at room temperature is possible. It is possible to manufacture an aluminum resin bonded body that has no problem in facilities and environment, can be easily operated and low in cost, and can exhibit excellent bonding strength between aluminum and resin over a long period of time.
- Example 1 (1) Production of surface-treated aluminum base material A 40 mm x 40 mm aluminum base material for joint strength test was cut out from a commercially available aluminum plate material (A5052; plate thickness 2.0 mm). Further, a 10 mm ⁇ hole was made in the center of the aluminum base material cut out to a size of 40 mm ⁇ 40 mm to prepare an aluminum base material for airtightness test.
- a zinc ion-containing sodium aqueous solution having a sodium hydroxide concentration of 100 g / L and a zinc oxide concentration of 25 g / L (20 g / L as Zn + ) was prepared as a film-forming treatment agent.
- the above-mentioned aluminum base material is immersed in this zinc ion-containing sodium aqueous solution at room temperature for 3 minutes, then washed with water, and a surface-treated aluminum for testing on which an oxygen-containing film containing zinc element is formed on the surface.
- a substrate was prepared.
- the obtained surface-treated aluminum base material was subjected to mapping analysis using EPMA (manufactured by Shimadzu: EPMA1610) and measuring 512 steps in the vertical and horizontal directions at an irradiation diameter of 40 ⁇ m / step. .
- the measurement area is 20.48 mm ⁇ 20.48 mm
- the sampling time for one step is 20 ms
- the acceleration voltage is 15 kV
- the resolution in the depth direction of oxygen is 3 ⁇ m or less.
- the detected oxygen intensity was calculated as a weight percentage (wt%) from a calibration curve prepared in advance.
- the calibration curve used was calculated and prepared from two points: the oxygen intensity of the Al 2 O 3 standard sample (oxygen amount: 48 wt%) and the oxygen intensity of the high-purity Al foil. The results are shown in Table 1.
- the surface-treated aluminum base material for testing obtained above is an injection molding machine.
- the PPS was injection molded under the injection molding conditions of a mold temperature of 150 ° C., a resin temperature of 320 ° C., an injection speed of 100 mm / s, a pressure holding pressure of 50 MPa, and a pressure holding time of 3 seconds, as shown in FIG.
- a PPS molded body 6 having a size of 520 mm ⁇ is molded, and the PPS molded body 6 is bonded to a zinc-containing film (not shown) of the surface-treated aluminum base material 7 with an area of 235.5 mm 2.
- An aluminum resin joined body 2 for an airtightness test was produced.
- a surface-treated aluminum base material 2 of an aluminum resin joined body 1 is fixed to a jig 4, and the upper end of the PPS molded body 3 is set at a speed of 1 mm / min.
- the bonding strength of the aluminum resin bonded body was evaluated. The results are shown in Table 1.
- Examples 2 to 9 Other than using the aluminum base having the materials shown in Table 1 and the zinc ion-containing alkaline aqueous solution having the liquid composition shown in Table 1 and adjusting the alkali hydroxide concentration and the zinc ion concentration to the concentrations shown in Table 1. Produced a test aluminum resin joined body in the same manner as in Example 1, and conducted an IR analysis, a joining strength, and an airtightness evaluation test on the resin portion in the same manner as in Example 1. The results are shown in Table 1.
- Example 10 to 11 The aluminum base material shown in Table 1 is used, soaked in 30wt% nitric acid aqueous solution for 5 minutes at room temperature, washed thoroughly with ion-exchanged water, and then immersed in 5wt% sodium hydroxide solution at 50 ° C for 1 minute. Then, it was washed with water, and further pretreated by immersing in a 30 wt% nitric acid aqueous solution at room temperature for 3 minutes and then washing with water. Next, an aluminum film formation treatment was performed by hydrating by immersing in hot water at 80 ° C. for 20 minutes, and an oxygen-containing film containing an aluminum compound AlO (OH) was formed on the surface of the aluminum base.
- a test aluminum resin joined body was prepared in the same manner as in Example 1, and IR analysis, joining strength, and airtightness evaluation tests were performed on the resin portion in the same manner as in Example 1. The results are shown in Table 1.
- Example 12 to 13 The aluminum base material shown in Table 1 is used, and laser etching is performed (device name: Miyachi Technos / ML-7112A, laser beam wavelength: 1064 nm, spot diameter: 50-60um, oscillation method: Q switch pulse, frequency : 10 kHz), a test aluminum resin joined body was prepared in the same manner as in Example 1 except that irradiation was performed in the same direction at a pitch width of 50 ⁇ m and a thermal oxide film (oxygen-containing film) was formed on the surface layer. In the same manner as in Example 1, the resin portion was subjected to IR analysis, bonding strength, and airtightness evaluation test. The results are shown in Table 1.
- Example 14 Except that polybutylene terephthalate (PBT) was used as the thermoplastic resin, a test aluminum resin joined body was produced in the same manner as in Example 1 above, and IR analysis and joining of the resin part was conducted in the same manner as in Example 1. An evaluation test of strength and airtightness was conducted.
- the injection molding conditions for PBT were as follows: mold temperature 100 ° C., resin temperature 250 ° C., injection speed 100 mm / s, holding pressure 50 MPa, holding pressure 2 seconds. The results are shown in Table 1.
- Example 15 Prior to the treatment with zinc-containing sodium hydroxide, a test aluminum resin joined body was prepared in the same manner as in Example 1 except that etching treatment using sodium hydroxide and desmut treatment with nitric acid were performed as pretreatment. The resin part was subjected to IR analysis, bonding strength and airtightness evaluation test in the same manner as in Example 1.
- the etching treatment with sodium hydroxide was an immersion treatment at 60 ° C. for 1 minute in a 5 wt% aqueous solution, and the desmut treatment with nitric acid was carried out at 25 ° C. for 3 minutes in a 10 wt% aqueous solution. The results are shown in Table 1.
- Comparative Example 1 A test aluminum resin joined body according to Comparative Example 1 was prepared and carried out in the same manner as in Example 1 except that the film forming step of forming the zinc-containing film using the film forming treatment agent was not performed. In the same manner as in Example 1, the resin portion was subjected to IR analysis, bonding strength, and airtightness evaluation test. The results are shown in Table 1.
- Example 2 After forming a zinc-containing film using a film-forming treatment agent, an electroless NiP plating treatment was further performed thereon, and the zinc-containing film was changed to a NiP plating film.
- a test aluminum resin joined body according to Example 2 was prepared, and an IR analysis, a joining strength, and an airtight evaluation test were performed on the resin portion in the same manner as in Example 1. The results are shown in Table 1.
- Example 3 Use the materials shown in Table 1 as the aluminum base material, soak it in a 30wt% nitric acid aqueous solution at room temperature for 5 minutes, and then wash it thoroughly with ion-exchanged water and dry it to have a natural oxide film on the surface of the aluminum base material.
- a test aluminum resin joined body was prepared in the same manner as in Example 1 except that an aluminum substrate was formed, and IR analysis, joining strength, and airtightness evaluation tests of the resin part were conducted in the same manner as in Example 1. went. The results are shown in Table 1.
- the aluminum resin bonded body of the present invention has excellent bonding strength before and after the durability test, it is suitably used for manufacturing various parts such as parts for various sensors for automobiles, parts for home appliances and parts for industrial equipment. Is possible.
- SYMBOLS 1 Aluminum resin joined body, 2 ... Surface treated aluminum base material, 3 ... Resin molded body, 4 ... Jig, 5 ... Load, 6 ... Resin molded body, 7 ... Surface treated aluminum base material, 8 ... For aluminum fixation Jig, 9 ... O-ring, 10 ... Airtightness test jig, 12 ... Clamp, 12 ... Leak tester.
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Abstract
Description
前記熱可塑性樹脂が、繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂であることを特徴とするアルミ樹脂接合体である。
前記熱可塑性樹脂が、繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂であることを特徴とするアルミ樹脂接合体の製造方法である。
前記熱可塑性樹脂が、繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂であることを特徴とするアルミ樹脂接合体の製造方法である。
なお、上記前処理として行う化学研磨処理や電解研磨処理については、従来公知の方法を採用することができる。
すなわち、アルミ基材の表面に酸素含有皮膜を有する複数の表面処理済アルミ基材を形成し、一部の表面処理済アルミ基材については、その表面にカルボニル基(C=O)を有するポリフェニレンスルフィド(PPS)の射出成形によりPPS成形体を接合してアルミPPS接合体とし、残りの表面処理済アルミ基材については、先ず、100℃に保持した電気炉中でステアリン酸を揮発させ、その中に表面処理済アルミ基材を24時間暴露し、酸素含有皮膜の上にステアリン酸の単分子膜を有するステアリン酸処理済アルミ基材とし、このステアリン処理済アルミ基材の表面にカルボニル基(C=O)を有するPPSの射出成形によりPPS成形体を接合してステアリン酸処理アルミPPS接合体とし、これらアルミPPS接合体とステアリン酸処理アルミPPS接合体との間における接合強度の違いを測定した。
結果は、ステアリン処理有アルミPPS接合体における接合強度は、アルミPPS接合体の接合強度に比べて明確に低下していた。
〔実施例1〕
(1) 表面処理済アルミ基材の作製
市販のアルミニウム板材(A5052; 板厚2.0mm)から40mm×40mmの大きさの接合強度試験用アルミ基材を切り出した。更に、40mm×40mmの大きさに切り出したアルミ基材の中央に10mmφの穴を開け、気密性試験用アルミ基材を作製した。また、皮膜形成処理剤として水酸化ナトリウム濃度100g/L及び酸化亜鉛濃度25g/L(Zn+として20g/L)の亜鉛イオン含有ナトリウム水溶液を調製した。次に、この亜鉛イオン含有ナトリウム水溶液中に上記のアルミ基材を室温下に3分間浸漬し、その後水洗し、表面に亜鉛元素を含有する酸素含有皮膜が形成された試験用の表面処理済アルミ基材を作製した。
得られた表面処理済アルミ基材について、EPMA(島津製:EPMA1610)を用い、照射径が40μm/stepで縦横方向にそれぞれ512step測定するマッピング分析を実施した。ここで、測定面積は20.48mm×20.48mmであり、1stepのサンプリングタイムは20msであって、加速電圧は15kVであり、酸素の深さ方向の分解能は3μm以下である。次に、検出された酸素強度を事前に作成した検量線から重量百分率(wt%)として算出した。なお、検量線は、Al2O3標準試料(酸素量:48wt%)の酸素強度と高純度Al箔の酸素強度の2点から算出し作成したものを使用した。
結果を表1に示す。
熱可塑性樹脂としてPPS(ポリプラスチックス社製商品名:フォートロン)を用い、上で得られた接合強度試験用表面処理済アルミ基材を射出成形機の金型内にセットし、金型温度150℃、樹脂温度320℃、射出速度100mm/s、保圧50MPa、保圧時間3秒の射出成形条件でPPSの射出成形を行い、図1に示すように、5mm×10mm×30mmの大きさのPPS成形体3を成形すると共に、このPPS成形体3を5mm×10mmの面積で表面処理済アルミ基材2の亜鉛含有皮膜(図示せず)上に接合させ、接合強度試験用のアルミ樹脂接合体1を作製した。
熱可塑性樹脂としてPPS(ポリプラスチックス社製商品名:フォートロン)を用い、上で得られた試験用表面処理済アルミ基材を射出成形機の金型内にセットし、金型温度150℃、樹脂温度320℃、射出速度100mm/s、保圧50MPa、保圧時間3秒の射出成形条件でPPSの射出成形を行い、図3に示すように、520mmφの大きさのPPS成形体6を成形すると共に、このPPS成形体6を235.5mm2の面積で表面処理済アルミ基材7の亜鉛含有皮膜(図示せず)上に接合させ、気密性試験用のアルミ樹脂接合体2を作製した。
このようにして作製された試験用アルミ樹脂接合体1及び2について、IR分析装置(Agilent Technologies 660FastImage-IR)を使用し、顕微ATR法により樹脂成形体部分のIR分析を実施し、カルボニル基(C=O)由来のピーク(1730cm-1付近)の有無を確認した。結果は、表1に示す通り、カルボニル基(C=O)由来のピークが検出された。
このようにして作製された試験用アルミ樹脂接合体について、アルミ樹脂接合体を温度85℃及び湿度85%の環境下に1000時間放置してアルミ樹脂接合体の耐食性を評価するアルミ樹脂接合体の耐久試験を行い、この耐久試験後のアルミ樹脂接合体について、下記の方法でそのアルミ-樹脂間の接合性(接合強度及び気密性)の評価試験を行った。
結果を表1に示す。
結果を表1に示す。
アルミ基材として表1に示す材質のものを使用し、亜鉛イオン含有アルカリ水溶液として表1に示す液組成のものを使用して水酸化アルカリ濃度及び亜鉛イオン濃度を表1に示す濃度にした以外は、実施例1と同様にして試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度、及び気密性の評価試験を行った。
結果を表1に示す。
アルミ基材として表1に示す材質のものを使用し、30wt%硝酸水溶液に常温で5分間浸漬した後にイオン交換水で十分に水洗し、次いで5wt%水酸化ナトリウム溶液に50℃で1分間浸漬した後に水洗し、更に、30wt%硝酸水溶液に常温で3分間浸漬した後に水洗する前処理を施した。次に、80℃の熱水で20分間浸漬させる水和処理をすることによりアルミニウム皮膜形成処理を施し、アルミ基材の表面にアルミニウム化合物AlO(OH)を含む酸素含有皮膜を形成した以外は、実施例1と同様にして試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度、及び気密性の評価試験を行った。
結果を表1に示す。
アルミ基材として表1に示す材質のものを使用し、レーザーエッチング処理(装置名:ミヤチテクノス/ML-7112A、レーザー光波長:1064nm、スポット径:50-60um、発振方式:Qスイッチパルス、周波数:10kHz)により、同一方向にピッチ幅50μm間隔で照射し、表層に熱酸化皮膜(酸素含有皮膜)を形成した以外は、実施例1と同様にして試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度、及び気密性の評価試験を行った。
結果を表1に示す。
熱可塑性樹脂としてポリブチレンテレフタレート(PBT)を使用した以外は、上記実施例1と同様にして、試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度及び気密性の評価試験を行った。なお、PBTの射出成形条件は金型温度100℃、樹脂温度250℃、射出速度100mm/s、保圧50MPa、保圧時間2秒の射出成形条件で行った、
結果を表1に示す。
亜鉛含有水酸化ナトリウムによる処理に先駆けて、前処理として水酸化ナトリウムを用いたエッチング処理と硝酸によるデスマット処理を実施した以外は、上記実施例1と同様にして、試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度及び気密性の評価試験を行った。なお、水酸化ナトリウムによるエッチング処理は5wt%水溶液で60℃1分の浸漬処理であり硝酸によるデスマット処理は10wt%水溶液で25℃3分実施した。
結果を表1に示す。
皮膜形成処理剤を用いて亜鉛含有皮膜を形成する皮膜形成工程を行わなかったこと以外は、上記実施例1と同様にして、比較例1に係る試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度、及び気密性の評価試験を行った。
結果を表1に示す。
皮膜形成処理剤を用いて亜鉛含有皮膜を形成した後、更にその上に無電解NiPメッキ処理を行い、亜鉛含有皮膜をNiPメッキ皮膜に変えた以外は、上記実施例1と同様にして、比較例2に係る試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度、及び気密性の評価試験を行った。
結果を表1に示す。
アルミ基材として表1に示す材質のものを使用し、30wt%硝酸水溶液に常温で5分間浸漬した後にイオン交換水で十分に水洗し、乾燥させ、アルミ基材の表面に自然酸化皮膜を有するアルミ基材を形成した以外は、実施例1と同様にして試験用のアルミ樹脂接合体を作製し、実施例1と同様にして樹脂部分のIR分析、接合強度、及び気密性の評価試験を行った。
結果を表1に示す。
Claims (18)
- アルミニウム又はアルミニウム合金からなるアルミ基材と、このアルミ基材の表面に形成された酸素を含有する酸素含有皮膜と、この酸素含有皮膜の上に接合され、熱可塑性樹脂で形成された樹脂成形体とを有し、
前記熱可塑性樹脂が、繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂であることを特徴とするアルミ樹脂接合体。 - 樹脂成形体が接合される前の表面に酸素含有皮膜を有するアルミ基材は、その最表面から3μmの深さまでの表層においてEPMAで測定された酸素量が0.1~48重量%の範囲内であることを特徴とする請求項1に記載のアルミ樹脂接合体。
- 酸素含有皮膜の上に樹脂成形体を接合する接合方法が、射出成形又は熱圧着による方法であることを特徴とする請求項1又は2に記載のアルミ樹脂接合体。
- 酸素含有皮膜が、亜鉛イオン含有アルカリ水溶液を用いた亜鉛含有皮膜形成処理で得られた亜鉛元素を含有する皮膜であることを特徴とする請求項1~3のいずれかに記載のアルミ樹脂接合体。
- 酸素含有皮膜が、湿式かつ無電解で行うアルミニウム皮膜形成処理に由来するAl(OH)3、AlO(OH)、Al2O3、Al(PO4)、Al2(HPO4)3、Al(H2PO4)3、及びAl(H2PO4)3からなる群から選ばれたいずれか1種又は2種以上のアルミニウム化合物を含む皮膜であることを特徴とする請求項1~3に記載のアルミ樹脂接合体。
- 酸素含有皮膜が、レーザー処理によりアルミ基材の表面に形成された皮膜であることを特徴とする請求項1~3に記載のアルミ樹脂接合体。
- 熱可塑性樹脂中に含まれる非共有電子対を持つ元素が、硫黄、酸素、及び窒素からなる群から選ばれたいずれか1種又は2種以上の元素であることを特徴とする請求項1~6のいずれかに記載のアルミ樹脂接合体。
- 繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂が、ポリフェニレンスルフィド系樹脂、ポリエステル系樹脂、ポリカーボネート系樹脂、ポリアセタール系樹脂、ポリエーテル系樹脂、ポリフェニレンエーテル系樹脂、ポリイミド系樹脂、ポリエーテルイミド系樹脂、液晶ポリマー、サルフォン系樹脂、ポリフェニレンオキサイド系樹脂、ポリアミド系樹脂、及びポリプロピレン系樹脂からなる群から選ばれたいずれか1種又は2種以上の樹脂であることを特徴とする請求項1~7のいずれかに記載のアルミ樹脂接合体。
- 樹脂成形体がカルボニル基(C=O)を有することを特徴とする請求項1~8のいずれかに記載のアルミ樹脂接合体。
- アルミニウム又はアルミニウム合金からなるアルミ基材の表面に酸素含有皮膜を形成する皮膜形成工程と、
この皮膜形成工程で得られた表面処理済アルミ基材の酸素含有皮膜の上に、熱可塑性樹脂の射出成形により樹脂成形体を形成する樹脂成形工程とを有し、
前記酸素含有皮膜を介してアルミ基材と樹脂成形体とが接合されたアルミ樹脂接合体を製造するアルミ樹脂接合体の製造方法であり、
前記熱可塑性樹脂が、繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂であることを特徴とするアルミ樹脂接合体の製造方法。 - アルミニウム又はアルミニウム合金からなるアルミ基材の表面に酸素含有皮膜を形成する皮膜形成工程と、
熱可塑性樹脂の射出成形により樹脂成形体を形成する樹脂成形工程と、
前記皮膜形成工程で得られた表面処理済アルミ基材の酸素含有皮膜の上に、前記樹脂成形工程で得られた樹脂成形体を熱圧着により接合するアルミ樹脂接合工程とを有し、
前記酸素含有皮膜を介してアルミ基材と樹脂成形体とが接合されたアルミ樹脂接合体を製造するアルミ樹脂接合体の製造方法であり、
前記熱可塑性樹脂が、繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂であることを特徴とするアルミ樹脂接合体の製造方法。 - 皮膜形成工程では、水酸化アルカリ(MOH)と亜鉛イオン(Zn+2)とを重量比(MOH/Zn+2)1~100の割合で含む亜鉛イオン含有アルカリ水溶液中にアルミ基材を浸漬する亜鉛含有皮膜形成処理により、このアルミ基材の表面に亜鉛元素を含有する酸素含有皮膜を形成することを特徴とする請求項10又は11に記載のアルミ樹脂接合体の製造方法。
- 亜鉛イオン含有アルカリ水溶液中のアルカリ源が、水酸化ナトリウム、水酸化カリウム、及び水酸化リチウムからなる群から選ばれたいずれか1種又は2種以上の水酸化アルカリであることを特徴とする請求項12に記載のアルミ樹脂接合体の製造方法。
- 亜鉛イオン含有アルカリ水溶液中の亜鉛イオン源が、酸化亜鉛、水酸化亜鉛、過酸化亜鉛、塩化亜鉛、硫酸亜鉛、及び硝酸亜鉛からなる群から選ばれたいずれか1種又は2種以上の亜鉛塩であることを特徴とする請求項12又は13に記載のアルミ樹脂接合体の製造方法。
- 皮膜形成工程では、アルミニウム又はアルミニウム合金からなるアルミ基材を、50℃以上の温水に60秒以上浸漬する温水浸漬処理、0.1MPa以上及び1分間以上の加圧条件下の水蒸気雰囲気中に晒す水蒸気処理、リン酸イオン、リン酸一水素イオン、及びリン酸二水素イオンからなる群から選ばれたいずれか1種又は2種以上のリン酸イオン種を0.1~100g/Lの範囲で含有するリン酸系水溶液中に30秒~30分間浸漬した後に80~400℃の熱風で30秒~30分間乾燥させるリン酸処理、又は陽極酸化処理から選ばれたいずれか1種のアルミニウム皮膜形成処理で処理し、このアルミ基材の表面にAl(OH)3、AlO(OH)、Al2O3、Al(PO4)、Al2(HPO4)3、Al(H2PO4)3、及びAlOSiO2から選ばれたいずれか1種又は2種以上のアルミニウム化合物を含有する酸素含有皮膜を形成することを特徴とする請求項10又は11に記載のアルミ樹脂接合体の製造方法。
- 皮膜形成工程では、アルミニウム又はアルミニウム合金からなるアルミ基材の表面付近を加熱するレーザー処理により酸素含有皮膜を形成することを特徴とする請求項10又は11に記載のアルミ樹脂接合体。
- 熱可塑性樹脂中に含まれる非共有電子対を持つ元素が、硫黄、酸素、窒素、及び炭素からなる群から選ばれたいずれか1種又は2種以上の元素であることを特徴とする請求項10~16のいずれかに記載のアルミ樹脂接合体の製造方法。
- 繰返し単位中及び/又は末端に非共有電子対を持つ元素を有する熱可塑性樹脂が、ポリフェニレンスルフィド系樹脂、ポリエステル系樹脂、ポリカーボネート系樹脂、ポリアセタール系樹脂、ポリエーテル系樹脂、ポリフェニレンエーテル系樹脂、ポリイミド系樹脂、ポリエーテルイミド系樹脂、液晶ポリマー、サルフォン系樹脂、ポリフェニレンオキサイド系樹脂、ポリアミド系樹脂、及びポリプロピレン系樹脂からなる群から選ばれたいずれか1種又は2種以上の樹脂であることを特徴とする請求項10~17のいずれかに記載のアルミ樹脂接合体の製造方法。
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WO2019064344A1 (ja) * | 2017-09-26 | 2019-04-04 | 住友理工株式会社 | 複合部材の製造方法 |
JP6351902B1 (ja) * | 2017-09-26 | 2018-07-04 | 住友理工株式会社 | 複合部材の製造方法 |
JP6396563B1 (ja) * | 2017-10-10 | 2018-09-26 | 奥野製薬工業株式会社 | 表面処理液 |
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WO2020158820A1 (ja) | 2019-01-29 | 2020-08-06 | 三井化学株式会社 | アルミニウム系金属樹脂複合構造体、アルミニウム系金属部材、アルミニウム系金属部材の製造方法およびアルミニウム系金属樹脂複合構造体の製造方法 |
EP4209617A1 (en) | 2019-01-29 | 2023-07-12 | Mitsui Chemicals, Inc. | Aluminum-based metal-resin composite structure, aluminum-based metal member, method for manufacturing aluminum-based metal member, and method for manufacturing aluminum-based metal-resin composite structure |
WO2021112175A1 (ja) * | 2019-12-06 | 2021-06-10 | 貴和化学薬品株式会社 | 金属表面前処理剤 |
JP2021123742A (ja) * | 2020-02-04 | 2021-08-30 | 学校法人 芝浦工業大学 | アルミニウム材料又はマグネシウム材料の表面処理方法 |
WO2022019339A1 (ja) | 2020-07-22 | 2022-01-27 | 三井化学株式会社 | 金属部材、金属樹脂複合体、及び金属部材の製造方法 |
Also Published As
Publication number | Publication date |
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TW201323221A (zh) | 2013-06-16 |
JPWO2013047365A1 (ja) | 2015-03-26 |
KR20140071444A (ko) | 2014-06-11 |
EP2762289A4 (en) | 2015-05-06 |
EP2762289A1 (en) | 2014-08-06 |
US20140234631A1 (en) | 2014-08-21 |
CN103826822A (zh) | 2014-05-28 |
JP2015166188A (ja) | 2015-09-24 |
JP5772966B2 (ja) | 2015-09-02 |
JP2016215654A (ja) | 2016-12-22 |
JP6004046B2 (ja) | 2016-10-05 |
KR101997941B1 (ko) | 2019-07-08 |
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