WO2013077277A1

WO2013077277A1 - Composite molding manufacturing method

Info

Publication number: WO2013077277A1
Application number: PCT/JP2012/079883
Authority: WO
Inventors: 奥村有道; 朝見芳弘; 北川友紀
Original assignee: 株式会社ダイセル; ダイセルポリマー株式会社
Priority date: 2011-11-21
Filing date: 2012-11-19
Publication date: 2013-05-30
Also published as: JP2013107273A; JP5848104B2; CN103946005A; KR20140095514A

Abstract

Provided is a manufacturing method with which composite moldings of increased joint strength between the metal molding and the resin molding are obtained. A composite molding manufacturing method comprising a laser irradiation process of forming multiple independent holes in a dot pattern on the junction surface of the metal molding, and a process of disposing the portion, which comprises the metal molding junction surface in which the multiple independent holes have been formed in a dot pattern, in a metal mold and insert-molding the resin that is to become the resin molding. The composite molding manufacturing method controls the ratio (dep/D) of the diameter (D) of the hole opening to the depth (dep) of the hole when a single hole is being formed in the laser irradiation process so as to be in the range of 1.0 - 10.

Description

Method for producing composite molded body

The present invention relates to a method for producing a composite molded body comprising a metal molded body and a resin molded body.
Background art

From the viewpoint of reducing the weight of various parts, resin molded bodies are used as metal substitutes, but it is often difficult to substitute all metal parts with resin. In such a case, it is conceivable to manufacture a new composite part by joining and integrating the metal molded body and the resin molded body.
However, a technique capable of joining and integrating a metal molded body and a resin molded body with an industrially advantageous method with high bonding strength has not been put into practical use.

Japanese Patent No. 4020957 discloses a metal surface for bonding with a dissimilar material (resin) including a step of laser scanning in one scanning direction and a step of laser scanning in a scanning direction crossing the metal surface. The invention of the laser processing method is described.
Japanese Patent Application Laid-Open No. 2010-167475 discloses an invention of a laser processing method in which laser scanning is performed in a superposed manner a plurality of times 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 need to be laser-scanned in two crossing directions, so there is room for improvement in that the processing time is too long. .
Furthermore, since sufficient surface roughening treatment can be performed by laser scanning in the cross direction, it is considered that the bonding strength can be increased, but the surface roughness state is not uniform, and the directionality of the strength of the bonded portion between the metal and the resin There is a problem that may not be stable.

In addition, when the joint surface has a complicated shape or a shape including a narrow portion (for example, a star shape, a triangle, or a dumbbell type), the surface is partially roughened by the laser scanning method in the cross direction. As a result of non-uniformity, it may be considered that sufficient bonding strength cannot be obtained.

Japanese Patent Application Laid-Open No. 10-294024 describes a method of manufacturing an electrical / electronic component in which a metal surface is irradiated with a laser beam to form irregularities, and a resin, rubber, or the like is injection-molded on the irregularity formation site.
In Embodiments 1 to 3, it is described that the surface of a long metal coil is irradiated with a laser to form irregularities. In paragraph No. 10, the surface of the long metal coil is roughened in a striped or satin shape. In paragraph No. 19, the surface of the long metal coil is roughened in a stripe, dotted, wavy, knurled, or satin. It is described.

However, as described in the effects of the inventions in

paragraphs

21 and 22, the purpose of laser irradiation is to form fine irregular irregularities on the metal surface, thereby enhancing the anchor effect. In particular, since the object to be processed is a long metal coil, it is considered that any irregularities are inevitably formed into fine irregular irregularities.
Therefore, the invention of Japanese Patent Laid-Open No. 10-294024 is the same technology as the invention of forming fine irregularities on the surface by laser irradiation in the cross direction as in the inventions of Japanese Patent Nos. 4020957 and 2010-167475. Disclosing the ideal idea.
Summary of the Invention

The present invention provides a composite molded body that can increase the bonding strength between a metal molded body and a resin molded body while reducing the laser irradiation area on the bonding surface of the metal molded body and suppressing the degree of surface roughening. It is an object to provide a manufacturing method.

As a means for solving the problems, the present invention
A step of irradiating a laser so as to form a plurality of independent dots in the shape of a joint on the metal molded body,
A method for producing a composite molded body comprising a step of placing a portion including a joining surface of a metal molded body in which a plurality of independent dots are formed in a mold, and insert molding a resin to be the resin molded body. There,
When forming one hole in the laser irradiation step, the ratio (dep / D) of the opening diameter (D) of the hole to the depth (dep) of the hole is in the range of 1.0 to 10. A method for producing a composite molded body is provided.

The present invention provides other means for solving the problems,
A step of irradiating a laser so that a groove composed of a plurality of holes is formed on the joint surface of the metal molded body,
A method for producing a composite molded body comprising a step of placing a portion including a joining surface of a metal molded body in which the groove is formed in a mold, and insert molding a resin to be the resin molded body,
When forming the groove in the laser irradiation process, a ratio (dep / W) of the groove width (W) to the groove depth (dep) is in the range of 1.0 to 10. A method for producing a molded body is provided.

The present invention provides a further solution to the problem,
A step of irradiating a laser so as to form a plurality of independent protrusions on the joint surface of the metal molded body,
A method for producing a composite molded body comprising a step of placing a portion including a joint surface of a metal molded body in which the plurality of convex portions are formed in a mold, and insert molding a resin to be the resin molded body,
When forming independent protrusions in the laser irradiation process, the ratio (h / Dis) between the distance (Dis) between adjacent protrusions and the height (h) of the protrusions is in the range of 1.0 to 10. Provided is a method for producing a composite molded body.

According to the production method of the present invention,
The ratio (d / D) of the opening diameter (D) and depth (d) of one hole formed in the laser irradiation step;
Ratio (d / W) of width (W) and depth (d) of groove formed in laser irradiation process or distance between adjacent protrusions of multiple protrusions formed in laser irradiation process (Dis) And (h / Dis) between the height of the convex portion (h),
Even when the laser irradiation (laser scan) range is narrower than before by adjusting to a predetermined range (that is, even when the degree of surface roughening of the metal molded body is suppressed), Bonding strength between the metal molded body and the resin molded body can be increased.

FIG. 1 is a plan view for explaining a method of forming independent dots in the laser irradiation step of the present invention. FIG. 2 is a cross-sectional view in the thickness direction of a metal molded body including dot-like independent holes in the laser irradiation step of the present invention. FIG. 3A is a plan view for explaining the groove forming method in the laser irradiation step of the present invention, and FIG. 3B is a groove forming method having a laser irradiation pitch different from that in FIG. It is a top view for demonstrating. FIG. 4A is a plan view of a groove in the laser irradiation step of the present invention, and FIG. 4B is a cross-sectional view in the thickness direction of a metal molded body including the groove of FIG. 5 is a plan view for explaining a method of forming a convex portion in the laser irradiation step of the present invention. 6A is a cross-sectional view in the width direction of the convex portion formed in FIG. 5, and FIG. 6B is a cross-sectional view in the width direction of another embodiment. FIG. 7 is an explanatory diagram of a method of irradiating a metal molded body with a laser in the example. FIG. 8 is an explanatory diagram of a laser irradiation method for the metal molded body shown in FIG. FIG. 9 is a diagram for explaining a tensile test method for the composite molded body. FIG. 10 is a view showing a micrograph (450 ×) of the surface of the metal molded body after laser scanning in Example 4. FIG. 11 is a view showing a scanning electron micrograph (50 ×) of a cross section of a metal molded body after laser scanning in Example 4. In the figure, 10 is a metal molded body, 11 is a hole, 21-28 is a hole, 30 is a groove, and 41 is a convex part. Form for carrying out the invention

The method for producing the composite molded body of the present invention is based on the difference in the laser irradiation process on the surface of the metal molded body,
A manufacturing method (first manufacturing method) including a step of laser irradiation so as to form dot-shaped independent holes;
A manufacturing method (second manufacturing method) including a step of irradiating a laser so that a groove including a plurality of holes is formed (that is, laser scanning);
It can be divided into a manufacturing method (third manufacturing method) having a step of laser irradiation (that is, laser scanning) so that a plurality of independent convex portions are formed.

(1) 1st manufacturing method <Laser irradiation process>
The laser irradiation step in the first manufacturing method is a step of performing laser irradiation so as to form a large number of dot-like independent holes on the surface of the metal molded body 10 to be a joint surface with the resin molded body.
In this laser irradiation step, a large number of independent holes 11 (11a, 11b, 11c, etc.) are formed as shown in FIG.

A large number of dot-like independent holes 11 are formed at a predetermined interval (pitch) as shown in FIG.
The pitches P1, P2,... Between the numerous dot-like independent holes 11 (11a, 11b, 11c...) Are preferably 30 to 300 μm in order to increase the bonding strength with the resin molding, It is preferable that it is 150 micrometers. The distance between the pitches P1 and P2 is the distance between the center points of the

adjacent holes

11a and 11b and the

holes

11b and 11c.
The distances between the pitches P1 and P2 are preferably set to be the same, but can be partially different. For example, when laser scanning is performed on a square surface, a uniform pitch is used when forming dot-shaped holes along each side, and a narrow pitch is used when laser irradiation is performed along corners. be able to.

A large number of dot-like independent holes 11 have a cross-sectional shape as shown in FIGS. 2 (a) to 2 (d), for example.
One hole 11 has a ratio (dep / D) of a hole opening diameter (D) to a hole depth (dep) in the range of 1.0 to 10, preferably 1.2 to 8. 0.0, more preferably in the range of 1.5 to 5.0.
By adjusting (dep / D) to the above range, the bonding strength between the metal molded body and the resin molded body can be increased even when the laser irradiation range is narrower than before.

The opening diameter (D) of the hole 11 is preferably 30 to 200 μm, more preferably 50 to 150 μm. The depth (dep) of the hole 11 is preferably adjusted to be within 50% of the thickness of the metal molded body 10 in order to maintain the strength of the metal molded body 10.

When one hole 11 (11a to 11c) as shown in FIGS. 1 and 2 is formed in the laser irradiation step, 1 to 400 shots of pulsed laser may be irradiated to form one independent hole 11. It is preferable to irradiate 1 to 200 shots of a pulse laser.
Moreover, the opening part diameter (D) of the hole 11 can also be expanded by irradiating, shifting a laser irradiation position.

When forming one hole 11 (11a to 11c) as shown in FIGS. 1 and 2 in the laser irradiation step, the beam diameter of the laser to be irradiated may be the same, or for each shot or multiple times It may be different for each shot.
In the case of the hole 11 in FIG. 1A, irradiation is performed with the same laser beam diameter.
In the case of the hole 11 in FIG. 1B, the laser beam diameter is gradually reduced for irradiation.
In the case of the hole 11 in FIG. 1C, it can be obtained by changing the irradiation angle of the laser beam.
In the case of the hole 11 shown in FIG. 1D, irradiation is first performed with a beam having the same diameter, and then irradiation with a beam having a smaller diameter.

In the laser irradiation step, laser irradiation is performed so as to form a large number of dot-shaped independent holes on the joint surface of the metal molded body. As a whole, a straight line (dotted line), a curved line (curved line), Marking can be performed by forming a figure or the like consisting of a curve.
For example, when laser irradiation is applied to the end face of a round bar with a circular cross section (joint surface of a metal molded body), laser irradiation is performed to form a plurality of concentric circles having different diameters, or laser irradiation is performed to form a spiral. It is possible to irradiate a laser beam in the shape of many polka dots.
In addition, laser irradiation can be performed in the same manner as in the circular shape described above, depending on the shape (triangle, square, hexagon, ellipse, indeterminate shape, etc.) of the joint surface of the metal molded body.

In the first production method, the metal molded body to which the laser irradiation step is applied is not particularly limited, and a molded body made of a known metal can be appropriately selected according to the application. For example, the molded object chosen from iron, various stainless steel, aluminum or its alloy, copper, magnesium, and an alloy containing them can be mentioned.

A known laser can be used in the laser irradiation step of the first production method, for example, YAG laser, semiconductor laser, glass laser, ruby laser, He—Ne laser, nitrogen laser, chelate laser, and dye laser are used. be able to.

<Insert molding process>
In the insert molding step in the first manufacturing method, a portion including a joining surface of a metal molded body in which a large number of dot-like independent holes are formed is placed in a mold, and the resin to be the resin molded body is insert molded. It is a process to do.

The insert molding method is not particularly limited, and a method of injecting a molten thermoplastic resin, thermoplastic elastomer or thermosetting resin (prepolymer) into a mold, and heating and pressing a metal molded body and a resin molded body. It is possible to apply a method or the like. When a thermosetting resin (prepolymer) is used, post-curing treatment is performed.

The thermoplastic resin can be appropriately selected from known thermoplastic resins depending on the application. For example, polyamide-based resins (aliphatic polyamides such as PA6 and PA66, aromatic polyamides), copolymers containing styrene units such as polystyrene, ABS resin, AS resin, polyethylene, copolymers containing ethylene units, polypropylene, propylene Examples thereof include copolymers containing units, other polyolefins, polyvinyl chloride, polyvinylidene chloride, polycarbonate resins, acrylic resins, methacrylic resins, polyester resins, polyacetal resins, and polyphenylene sulfide resins.

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

The thermoplastic elastomer can be appropriately selected from known thermoplastic elastomers according to the application. Examples thereof include styrene elastomers, vinyl chloride elastomers, olefin elastomers, urethane elastomers, polyester elastomers, nitrile elastomers, and polyamide elastomers.

These thermoplastic resins, thermosetting resins, and thermoplastic elastomers can be blended with known fibrous fillers.
Examples of known fibrous fillers include carbon fibers, inorganic fibers, metal fibers, and organic fibers.
Carbon fibers are well known, and PAN-based, pitch-based, rayon-based, etc. can be used, but PAN-based and pitch-based ones are preferred.
Examples of the inorganic fiber include glass fiber, basalt fiber, silica fiber, silica / alumina fiber, zirconia fiber, boron nitride fiber, and silicon nitride fiber, and glass fiber is preferable.
Examples of the metal fiber include fibers made of stainless steel, aluminum, copper, and the like, and stainless steel fibers are preferable.
Organic fibers include polyamide fibers (fully aromatic polyamide fibers, semi-aromatic polyamide fibers in which either diamine or dicarboxylic acid is an aromatic compound, aliphatic polyamide fibers), polyvinyl alcohol fibers, acrylic fibers, polyolefin fibers, Polyoxymethylene fiber, polytetrafluoroethylene fiber, polyester fiber (including wholly aromatic polyester fiber), polyimide fiber, liquid crystal polyester fiber, polyphenylene sulfide fiber, cellulose fiber, and regenerated cellulose fiber can be used. More preferred are wholly aromatic polyamide fibers (aramid fibers), cellulose fibers, and regenerated cellulose fibers.

As these fibrous fillers, those having a fiber diameter in the range of 3 to 60 μm can be used. Among these, for example, the holes of the marking pattern 5 formed on the joint surface 1a of the metal molded body 1 are used. It is preferable to use a fiber having a smaller fiber diameter than the opening diameter (D).
When a fibrous filler having a fiber diameter smaller than the opening diameter (D) of the hole of the marking pattern 5 is used, a part of the fibrous filler has entered the hole of the marking pattern 5 of the metal molded body. This is preferable because a composite molded body in a state is obtained and the bonding strength between the metal molded body and the resin molded body is increased.
The blending amount of the fibrous filler with respect to 100 parts by mass of the thermoplastic resin, thermosetting resin, and thermoplastic elastomer is preferably 5 to 250 parts by mass.

<Second production method>
The laser irradiation step in the second manufacturing method is a step of performing laser irradiation (laser scanning) so that a groove composed of a plurality of holes is formed on the surface of the metal molded body 10 which is a bonding surface with the resin molded body. It is.
In this laser scanning process, as shown in FIGS. 3A and 3B, a large number of holes 21 to 28 and the like are formed so as to overlap each other, so that the groove 30 as a whole is formed as shown in FIG. Is a step of forming. 3 (a) and 3 (b) are examples in which the interval (pitch) between the holes is different, and the pitch in FIG. 3 (b) is larger. Here, the pitch is the same as P1 and P2 shown in FIG. 1, and is the distance between the centers of adjacent holes.

For example, the groove 30 has a cross-sectional shape as shown in FIG.
The groove 30 has a ratio (dep / W) of the groove width (W) to the groove depth (dep) in the range of 1.0 to 10, preferably 1.2 to 8.0. The range of 1.5 to 5.0 is preferable.
By adjusting (W / dep) to the above range, the bonding strength between the metal molded body and the resin molded body can be increased even when the laser irradiation range is narrower than before.

The width of the groove 30 is preferably 30 to 200 μm, more preferably 50 to 150 μm. In order to maintain the strength of the metal molded body 10, the depth of the holes 11 is preferably adjusted to be within 50% of the thickness of the metal molded body 10.

The laser scanning speed can be selected according to the laser output, and can generally be selected within the range of 0.1 to 20000 mm / sec, preferably 1 to 12000 mm / sec, more preferably 5 to 2000 mm / sec, 10 More preferably, it is ˜1000 mm / sec.
The distance between adjacent grooves (distance between the width intermediate points of adjacent grooves) is preferably 30 to 300 μm, and more preferably 40 to 150 μm.

In the laser scanning process, laser irradiation is performed so as to form a groove on the joint surface of the metal molded body. However, marking may be performed so as to form a straight line, a curved line, a straight line and / or a figure composed of a curved line as a whole. it can.
For example, when laser irradiation is applied to the end face of a round bar with a circular cross section (joint surface of a metal molded body), laser irradiation is performed to form a plurality of concentric circles having different diameters, or laser irradiation is performed to form a spiral. It is possible to irradiate a laser beam in the shape of many polka dots.
In addition, laser irradiation can be performed in the same manner as in the circular shape described above, depending on the shape (triangle, square, hexagon, ellipse, indeterminate shape, etc.) of the joint surface of the metal molded body.

The metal molded body to which the laser scanning process in the second production method is applied is not particularly limited, and a molded body made of a known metal can be appropriately selected according to the application. For example, the molded object chosen from iron, various stainless steel, aluminum or its alloy, copper, magnesium, and an alloy containing them can be mentioned.

A known laser can be used in the laser scanning step of the second production method, for example, a YAG laser, a semiconductor laser, a glass laser, a ruby laser, a He—Ne laser, a nitrogen laser, a chelate laser, or a dye laser is used. be able to.

The same method as the first manufacturing method can be applied to the insert molding step of the second manufacturing method.
When a fibrous filler is used as the molding material for the resin molding, one having a fiber diameter in the range of 3 to 60 μm can be used. Among these, it is preferable to use a fiber having a fiber diameter smaller than the width (W) of the groove of the marking pattern 5 formed on the bonding surface 1a of the metal molded body 1, for example.
When a fibrous filler having a fiber diameter smaller than the width (W) of the groove of the marking pattern 5 is used, a part of the fibrous filler enters the groove of the marking pattern 5 of the metal molded body. A composite molded body is obtained, which is preferable because the bonding strength between the metal molded body and the resin molded body can be increased.

<Third production method>
The laser irradiation step in the third manufacturing method is a step of performing laser irradiation (laser scanning) so as to form a plurality of independent convex portions on the joint surface of the metal molded body.
In this laser scanning step, laser irradiation is performed so that a plurality of independent convex portions 41 as shown in FIG. 5 are formed on the surface of the metal molded body 10 which is a joint surface with the resin molded body.
In order to form such a plurality of independent convex portions 41, the metal removal surface 42 including the concave portions (grooves) is formed by laser scanning the surface of the metal molded body 10 on which the convex portions 41 are not formed.
In order to form the convex portion 41 (and the metal removal surface 42) having such a predetermined height, a method of performing laser scanning a plurality of times on the joint surface of the metal molded body 10 can be applied.
When the number of scans is increased, the height (h) of the convex portion is relatively high, and when the number of scans is decreased, the height of the convex portion (h) is relatively low.

The plurality of independent convex portions 41 are formed with a predetermined interval between adjacent convex portions 41 as shown in FIG.
The distance (Dis) between the adjacent convex portions 41 is preferably 40 to 250 μm, more preferably 80 to 200 μm.
The distance (Dis) between the adjacent convex portions 41 is preferably set to be the same, but can be partially different. For example, when laser scanning is performed on a square surface, a uniform pitch is used when forming dot-shaped holes along each side, and a narrow pitch is used when laser irradiation is performed along corners. be able to.
The interval (W) between adjacent convex portions 41 is preferably 30 to 200 μm, and more preferably 50 to 150 μm.
For example, as shown in FIG. 5, when the planar shape of the convex portion 41 is a square, the width (length of one side) is preferably 30 to 200 μm, and more preferably 50 to 150 μm.

The independent convex part 41 has a cross-sectional shape as shown in FIGS. 6 (a) and 6 (b), for example.
The height (h) of the convex portion 41 is preferably adjusted to be within 50% of the thickness of the metal molded body 10 in order to maintain the strength of the metal molded body 10.
The plurality of independent convex portions 41 have a ratio (h / Dis) between the distance (Dis) between the adjacent convex portions 41 and the height (h) of the convex portions 41 in the range of 1.0 to 10. And preferably in the range of 1.2 to 8, more preferably 1.5 to 5.
By adjusting (h / Dis) to the above range, even if the laser irradiation range is narrower than before, the bonding strength between the metal molded body and the resin molded body can be increased.

In the laser irradiation step, laser irradiation is performed so as to form a large number of independent protrusions on the joint surface of the metal molded body 10, but the entire protrusion is a straight line (dotted line), a curve (curved line), a straight line. And / or marking can be performed so as to form a figure made of a curve.
For example, when laser irradiation is applied to the end face of a round bar having a circular cross section (joint surface of a metal molded body), laser irradiation is performed so as to form a plurality of concentric circles having different diameters as the entire convex portion, or spirals are formed as the entire convex portion. Laser irradiation can be performed so as to form, or laser irradiation can be performed in the form of a number of polka dots as the entire convex portion.
In addition, laser irradiation can be performed in the same manner as in the circular shape described above, depending on the shape (triangle, square, hexagon, ellipse, indeterminate shape, etc.) of the joint surface of the metal molded body.

The metal molded body to which the laser scanning step in the third production method is applied is not particularly limited, and a molded body made of a known metal can be appropriately selected according to the application. For example, the molded object chosen from iron, various stainless steel, aluminum or its alloy, copper, magnesium, and an alloy containing them can be mentioned.

A known laser can be used in the laser scanning step of the third manufacturing method, for example, a YAG laser, a semiconductor laser, a glass laser, a ruby laser, a He—Ne laser, a nitrogen laser, a chelate laser, or a dye laser is used. be able to.

The same method as the first manufacturing method can be applied to the insert molding step of the third manufacturing method.
When a fibrous filler is used as the molding material for the resin molding, one having a fiber diameter in the range of 3 to 60 μm can be used. Among these, for example, it is preferable to use a fiber having a smaller fiber diameter than the interval (W) between the protrusions formed on the joint surface of the metal molded body 10.
When a fibrous filler having a fiber diameter smaller than the interval (W) between the convex portions of the marking pattern 5 is used, a part of the fibrous filler is present between the convex portions of the marking pattern 5 of the metal molded body. A composite molded body in an intruded state is obtained, which is preferable because the bonding strength between the metal molded body and the resin molded body is increased.
Example

<Measurement method>
(1) Hole diameter (D), groove width (W), and distance between protrusions (Dis)
An image was taken from above the metal joint surface processed by laser irradiation using a CCD (Keyence's digital microscope VHX, lens VH-Z450) in a state where the top surface of the uneven surface is in focus at a lens magnification of 450 times. .
With respect to the hole diameter (D), the dimension of D in the portion in focus on the image was measured at 15 points, and the average value was obtained.
For the groove width (W), the W dimension was similarly measured at 15 points, and the average value was obtained.
Similarly, for the distance (Dis) between the convex portions, 15 points of the Dis interval were measured, and the average value was obtained. An example of a photomicrograph used for the measurement is shown in FIG.

(2) Hole depth (Dep), groove depth (Dep), and convex part height (h)
The composite molded body was cut with a diamond wire saw (DWS3242 manufactured by Meiwa Forsys).
The cutting was performed by rotating a diamond wire saw blade (circular blade) by 18 ° and cutting it into 10 test pieces in total.
After the cut surface of each test piece was embedded with an epoxy resin, the cross section was polished with a polishing machine (MA-200D manufactured by Musashino Electronics).
Thereafter, the polished cross section was observed with a scanning electron microscope (S-3400N manufactured by Hitachi High-Technologies Corporation) at a magnification of 50 times to obtain a cross-sectional image.
For each cross-sectional image, a line 1 passing through two or more points on the bottom surface (concave part) of the convex part is drawn with a visual field of 2 mm or more, and the vertex of the convex part passes through two or more points and is parallel to line 1 2 was subtracted.
The distance between the

lines

1 and 2 was measured, and the one with the largest distance was defined as the hole depth (Dep), the groove depth (Dep), and the height of the convex part (h). An example (Example 4) of the micrograph used for the measurement is shown in FIG.

Examples 1 and 2 (first manufacturing method)
A composite molded body made of a metal plate (SUS304) or aluminum plate (AL A5052) and polyamide 66 was produced.

YAG laser for laser irradiation area (bonding surface) 15 (40 mm ² [4 mm × 10 mm]) indicated by metal plate (SUS304 or AL (A5052)) (width 15 mm, length 60 mm, thickness 1 mm) shown in FIG. Was used, and laser irradiation was performed at an angle of 90 degrees with respect to the bonding surface 15 of the metal plate 10 (from directly above). The laser irradiation conditions are as shown in Table 1. A marking pattern made up of a large number of holes is shown in FIG.

After irradiating the joining surface 15 of the metal plate 10 with laser, insert molding was performed by the following method to obtain a composite molded body 30 in which the metal plate 10 and the resin molded body 20 shown in FIG. However, FIG. 9 shows a state in which the spacer 40 for the tensile test (the spacer 40 is not included in the composite molded body obtained by the method of the present invention) is attached.

<Insert molding (injection molding)>
Resin: GF60% reinforced PA66 resin (Plastotron PA66-GF60-01 (L9): manufactured by Daicel Polymer Co., Ltd.)
Resin temperature: 320 ° C
Mold temperature: 100 ° C
Injection molding machine: FUNAC ROBOSHOT S-2000i-100B

A tensile test was performed using the composite molded body 30 shown in FIG. The results are shown in Table 1.
<Tensile test conditions>
Testing machine: Tensilon UCT-1T
Tensile speed: 5mm / min
Distance between chucks: 50mm
Tensile direction: White arrow direction shown in FIGS. The test was performed by n number 5, and the average value was calculated | required.

Example 3 (second manufacturing method), Comparative Examples 1 and 2
According to the method of Example 1, laser scanning was performed under the laser irradiation conditions shown in Table 2.
Thereafter, insert molding was performed in the same manner as in Example 1 to form a composite molded body 30 (with a tensile test spacer 40) shown in FIG. 9, and a tensile test was further performed in the same manner as in Example 1. The results are shown in Table 2.

Comparative Examples 1 and 2 could not be measured because they were easily peeled off.
From the comparison of the tensile strength between Example 3 and Comparative Examples 1 and 2, it was confirmed that the bonding strength between the metal molded body and the resin molded body can be increased by controlling the dep / W ratio. This fact indicates that if the scanning range is the same, the bonding strength can be increased by performing the manufacturing method (laser scanning step) of the present invention.

Examples 4 to 7 (third manufacturing method)
The YVO4 laser (vanadium) is applied to the laser irradiation area (bonding surface) 15 (40 mm ² [4 mm × 10 mm]) indicated by the metal plate (AL (A5052)) (width 15 mm, length 60 mm, thickness 1 mm) shown in FIG. The laser was scanned at an angle of 90 degrees with respect to the bonding surface 15 of the metal plate 10 (from directly above). The laser scanning conditions are as shown in Table 3. A marking pattern composed of a large number of convex portions is shown in FIG. The convex portion was a quadrangular prism whose lower surface was a square with a side of 70 μm, and conditions were set so that W was 70 μm. Other detailed condition settings are shown in Table 3. The laser processing setting conditions and the dimensions of the actually formed convex portions are slightly different, and the dimensions are determined by CCD digital microscope (FIG. 10; Example 4) and scanning electron microscope observation (FIG. 11; Example 4). ).
Thereafter, insert molding was performed in the same manner as in Example 1 to form a composite molded body 30 (with a tensile test spacer 40) shown in FIG. 9, and a tensile test was further performed in the same manner as in Example 1. The results are shown in Table 3.

Claims

A step of irradiating a laser so as to form a plurality of independent dots in the shape of a joint on the metal molded body,
A method for producing a composite molded body comprising a step of placing a portion including a joining surface of a metal molded body in which a plurality of independent dots are formed in a mold, and insert molding a resin to be the resin molded body. There,
When forming one hole in the laser irradiation process, the ratio (dep / D) of the opening diameter (D) of the hole to the depth (dep) of the hole is in the range of 1.0 to 10. A method for producing a composite molded body.
The method for producing a composite molded body according to claim 1, wherein the (dep / D) is in the range of 1.2 to 8.0.
The method for producing a composite molded body according to claim 1 or 2, wherein the opening diameter (D) of the hole is 30 to 200 µm, and the depth (dep) of the hole is within 50% of the thickness of the metal molded body.
Laser irradiation is performed so that a plurality of dot-like independent holes are formed on the joint surface of the metal molded body, and a straight line, a curve formed from the plurality of holes, and a desired shape made of them. The method for producing a composite molded body according to any one of claims 1 to 3, wherein the method is a step of marking on the surface.
A step of irradiating a laser so that a groove composed of a plurality of holes is formed on the joint surface of the metal molded body,
A method for producing a composite molded body comprising a step of placing a portion including a joining surface of a metal molded body in which the groove is formed in a mold, and insert molding a resin to be the resin molded body,
When forming the groove in the laser irradiation step, the ratio (dep / W) of the groove width (W) to the groove depth (dep) is in the range of 1.0 to 10. Manufacturing method of a molded object.
The method for producing a composite molded body according to claim 1, wherein the (dep / W) is in the range of 1.2 to 8.0.
3. The method for producing a composite molded body according to claim 1, wherein the groove width (W) is 30 to 200 μm and the groove depth (dep) is within 50% of the thickness of the metal molded body.
The laser irradiating step is a step of performing laser scanning so as to form a groove on the joint surface of the metal molded body and marking a straight line, a curved line made of the groove, and a desired shape made of the groove. 8. The method for producing a composite molded body according to any one of 7 above.
A step of irradiating a laser so as to form a plurality of independent protrusions on the joint surface of the metal molded body,
A method for producing a composite molded body comprising a step of placing a portion including a joint surface of a metal molded body having a plurality of independent protrusions in a mold and insert molding a resin to be the resin molded body. And
When forming convex portions in the laser irradiation process, the ratio (h / Dis) between the distance between adjacent convex portions (Dis) and the height (h) of the convex portions is in the range of 1.0 to 10. A method for producing a composite molded body.
The method for producing a composite molded body according to claim 9, wherein the (h / Dis) is in the range of 1.2 to 8.0.
The composite molded body according to claim 1 or 2, wherein the distance (Dis) between the adjacent convex portions is 40 to 250 µm, and the height (h) of the convex portions is within 50% of the thickness of the metal molded body. Production method.
Laser irradiation is performed so that a plurality of independent convex portions are formed on the joint surface of the metal molded body, and a straight line, a curve formed from the plurality of independent convex portions, and a desired shape made of them. The method for producing a composite molded body according to any one of claims 9 to 11, which is a step of marking a shape.