WO2014156988A1 - 複合成形体の製造方法 - Google Patents
複合成形体の製造方法 Download PDFInfo
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- WO2014156988A1 WO2014156988A1 PCT/JP2014/057836 JP2014057836W WO2014156988A1 WO 2014156988 A1 WO2014156988 A1 WO 2014156988A1 JP 2014057836 W JP2014057836 W JP 2014057836W WO 2014156988 A1 WO2014156988 A1 WO 2014156988A1
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- molded body
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- resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
- B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/362—Laser etching
- B23K26/364—Laser etching for making a groove or trench, e.g. for scribing a break initiation groove
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/40—Removing material taking account of the properties of the material involved
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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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
- B23K2103/05—Stainless steel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/12—Copper or alloys thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/15—Magnesium or alloys thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/16—Composite materials, e.g. fibre reinforced
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/30—Organic material
- B23K2103/42—Plastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
-
- 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
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- 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
Definitions
- the present invention relates to a method for producing a composite molded body comprising a metal molded body and a resin molded body.
- 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 multiple times in the invention of Japanese Patent No. 4020957.
- the bonded body of the above may have the highest shearing force and tensile strength in the Z-axis direction different from the X-axis and Y-axis directions.
- a metal / resin composite having high bonding strength in a specific direction may be required, but Patent No. 4020957 In the invention of Japanese Patent Laid-Open No. 2010-167475, the above-mentioned demand cannot be sufficiently met.
- 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.
- a metal surface is irradiated with a laser beam to form irregularities
- a resin, rubber, or the like is injection-molded on the irregularity formation site.
- the surface of a long metal coil is irradiated with a laser to form irregularities.
- the surface of the long metal coil is roughened in a striped or satin shape.
- paragraph No. 19 the surface of the long metal coil is roughened in a stripe, dotted, wavy, knurled, or satin. It is described.
- the purpose of laser irradiation is to form fine irregular irregularities on the metal surface, thereby enhancing the anchor effect.
- 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.
- International Publication 2012/090671 is an invention of a method for producing a composite molded body comprising a metal molded body and a resin molded body. It is a laser scanning process to form markings consisting of straight lines and / or curves in one direction or different directions with respect to the joint surface of the metal molded body, and the markings consisting of straight lines and / or curves do not intersect each other. Laser scanning step.
- FIGS. 6 to 9 show square, circular, elliptical, and triangular marking patterns.
- An object of the present invention is to provide a method for producing a composite molded body, which can produce a composite molded body with higher bonding strength.
- the present invention A method for producing a composite molded body in which a metal molded body and a resin molded body are joined, A groove is formed by irradiating a laser beam having a laser spot diameter of 10 to 200 ⁇ m to the joint surface of the metal molded body, thereby forming a circle having a diameter of 20 to 1000 ⁇ m or one region having the same area.
- a method for manufacturing a body is provided.
- the bonding strength between the metal molded body and the resin molded body can be increased.
- FIG. 1 is a cross-sectional view (including a partially enlarged view) in the thickness direction of a composite molded body obtained by the production method of the present invention.
- FIG. 2 is a cross-sectional view in the diameter direction of a composite molded body according to another embodiment of the present invention, where (a) is a view seen from the side, and (b) is a view seen from the end face.
- FIG. 3 is an explanatory view of the production method of the present invention, which is a plan view (right side) and a partially enlarged view (left side).
- FIG. 4 is a diagram showing a formation pattern of a region surrounded by grooves in the manufacturing method of the present invention.
- FIG. 5 is an explanatory diagram of a manufacturing method in the embodiment.
- FIG. 6 (a) is an SEM photograph of a plan view of a metal molded body used in the composite molded body of Example 1
- FIG. 6 (b) is an enlarged view of FIG. 6 (a)
- FIG. 6 (c). ) Is an SEM photograph of the cross section in the thickness direction of FIG.
- FIG. 7 is an explanatory diagram of the manufacturing method of Comparative Example 1.
- FIG. 8 is a diagram for explaining a method of measuring the bonding strength of the composite molded bodies of the example and the comparative example.
- FIG. 1 is a cross-sectional view (including a partially enlarged view) in the thickness direction of a composite molded body 1 in which a flat metal molded body 10 and a flat resin molded body 20 are joined and integrated between flat surfaces.
- FIG. 2A is a cross-sectional view in the thickness (diameter) direction of a composite molded body 1 in which a cylindrical (round bar) metal molded body 10 and a cylindrical resin molded body 20 are joined and integrated with curved surfaces.
- . 1 and 2 can be manufactured through the following first step, second step and third step.
- the laser spot diameter (d) is in the range of 10 to 200 ⁇ m with respect to the joint surface of the metal molded body 10 before being joined and integrated.
- a groove 31 is formed by irradiating a laser beam, and a circle having a diameter (D) of 20 to 1000 ⁇ m or one region having the same area is formed. Further, in the first step, the groove 31 is formed so that the start point and the end point of laser irradiation are connected by one scan, and this is repeated a plurality of scans so that the same groove 31 is formed.
- One region (circular region) 30 having a convex portion 32 is formed inside 31.
- the diameter D of one region (circular region) 30 formed by the groove 31 and the convex portion 32 is the diameter of the contact circle outside the laser spot.
- the groove 31 is formed so that the start point and the end point of laser irradiation are connected by one scan. That is, laser irradiation is performed such that laser spots adjacent in the circumferential direction overlap or contact each other.
- the same groove 31 is scanned a plurality of times as in the first scan.
- the depth of the groove 31 (that is, the height of the convex portion 32) is adjusted by scanning a plurality of times.
- One region 30 surrounded by the groove 31 in the first step is not limited to a circle, an ellipse, a triangle, a rectangle, a pentagon or more polygon, and a desired shape as shown in FIGS.
- the region may be selected from an indefinite shape, and may be a region having a shape other than that.
- the diameter (D) is set to a circle having a diameter of 20 to 1000 ⁇ m or one region having the same area.
- the laser spot diameter (d) is 10 to 200 ⁇ m, preferably 10 to 100 ⁇ m, more preferably 10 to 50 ⁇ m.
- the size of one region is a circle having a diameter (D) of 20 to 1000 ⁇ m or the same area range, preferably a circle having a diameter (D) of 20 to 500 ⁇ m or the same area range, more preferably a diameter.
- (D) is a circle of 20 to 300 ⁇ m or the same area range.
- the irradiation distance for one scan is preferably 100 to 100,000 ⁇ m, more preferably 100 to 10,000 ⁇ m, and further preferably 100 to 1000 ⁇ m.
- the depth of the groove formed by laser beam irradiation for one scan is preferably 5 to 300 ⁇ m, and more preferably 10 to 300 ⁇ m.
- the depth of the groove after full scanning is preferably 10 to 600 ⁇ m, and more preferably 10 to 300 ⁇ m.
- the irradiation conditions of the laser beam when forming the region 30 composed of such grooves are as follows.
- the output is preferably 4 to 4000 W.
- the wavelength is preferably from 300 to 1200 nm, more preferably from 500 to 1200 nm.
- the pulse width for one scan (irradiation time of laser light for one scan) is preferably 1 to 10,000 nsec.
- the frequency is preferably 1 to 100 kHz.
- the focal position is preferably ⁇ 10 to +10 mm, more preferably ⁇ 6 to +6 mm.
- the processing speed is preferably 10 to 10,000 mm / sec, more preferably 100 to 10,000 mm / sec, and further preferably 300 to 10,000 mm / sec.
- the number of scans is preferably 1 to 30 times.
- ⁇ Second step> In the second step, the first step is repeated to form a plurality of regions 30 (30a to 30g) shown in FIGS. 4A to 4G on the joint surface 12 of the metal molded body 10. 4A to 4E, regions 30 (30a to 30e) are formed on the entire surface of the bonding surface 12. In FIGS. 4F and 4G, regions are formed on a part of the bonding surface 12. 30 (30f, 30g) is formed.
- a plurality of circular regions 30a having grooves 31a and convex portions 32a are formed at equal intervals.
- the plurality of circular regions 30a are independent from each other and are not in contact with each other, but the grooves 31a of all or part of the regions 30a may overlap each other.
- a plurality of elliptical regions 30b having grooves 31b and convex portions 32b are formed at equal intervals.
- the plurality of oval regions 30b are independent and are not in contact with each other, but the grooves 31b of all or some of the regions 30b may overlap each other.
- a plurality of triangular regions 30c having grooves 31c and convex portions 32c are formed at equal intervals.
- the plurality of triangular regions 30c are independent from each other and are not in contact with each other, but the grooves 31c of all or some of the regions 30c may overlap each other.
- a plurality of rectangular regions 30d having grooves 31d and convex portions 32d are formed at equal intervals.
- the plurality of quadrangular regions 30d are independent of each other and are not in contact with each other, but the grooves 31d of all or some of the regions 30d may overlap each other.
- a plurality of circular regions 30e having grooves 31e and convex portions 32e are formed at equal intervals in a different arrangement state from FIG. 4 (a).
- the plurality of circular regions 30e are independent and are not in contact with each other, but the grooves 31e of all or some of the regions 30e may overlap each other.
- FIG. 4 (f) unlike FIGS. 4 (a) and 4 (e), a plurality of circular regions 30f having grooves 31f and convex portions 32f are formed on a part of the joint surface 12.
- FIG. The plurality of circular regions 30f are independent and are not in contact with each other, but the grooves 31f of all or some of the regions 30f may overlap each other.
- FIG. 4F in the plurality of circular regions 30f, the formation density of the circular region 30f on the side 12a side of the joint surface 12 is high, and the formation density of the circular region 30f on the opposite side 12b side is low. Is formed. In this manner, the circular regions 30f are not evenly arranged on the joint surface 12 and can be formed so as to be unevenly distributed on a part of the surface.
- the composite molded body 1 shown in FIG. 1 has a plurality of circular regions 30f shown in FIG. 4 (f) formed on the joining surface 12, the circular regions 30f are dense on the side 12a side. Since it is formed, the drag force when the composite molded body 1 is pulled in the direction of the arrow in FIG. 4F is increased, and the bonding strength between the metal molded body 10 and the resin molded body 20 is increased.
- a plurality of circular regions 30g having grooves 31g and convex portions 32g are formed around the joint surface 12, and a central portion is formed.
- the circular region 30g is not formed.
- the plurality of circular regions 30g are independent of each other and are not in contact with each other, but the grooves 31g of all or some of the regions 30g may overlap each other.
- a plurality of circular regions 30g may be formed only in the central portion of the joint surface 12, and the circular regions 30g may not be formed in the periphery.
- ⁇ Third step> a portion including the joint surface 12 of the metal molded body 10 in which a plurality of regions 30 are formed is placed in a mold, and insert molding is performed using a resin that becomes the resin molded body 20, A composite molded body 1 is obtained.
- the composite molded body 1 in a state where the resin enters the groove 31 of the region 30 (the groove 31 and the protrusion 32) is obtained. Since the metal molded body 10 has the region 30 (the groove 31 and the protrusion 32) as described above, the contact area between the metal molded body 10 and the resin molded body 20 is increased, and the resin is contained in the groove 31.
- the joint strength is enhanced by the anchor effect caused by the penetration. Further, for example, as shown in FIGS. 4A to 4G, the tensile strength and the bending strength in the desired direction are increased by adjusting the arrangement state of the region 30 and adjusting the formation pattern. A composite molded body can be obtained.
- the metal of the metal molded body used in the composite molded body of the present invention is not particularly limited, and can be appropriately selected from known metals according to applications. Examples thereof include those selected from iron, various stainless steels, aluminum or alloys thereof, copper or alloys thereof, silver or alloys thereof, zinc, magnesium, lead, tin and alloys containing them.
- the molding method of the metal molded body used in the composite molded body of the present invention is not particularly limited, and can be produced by applying various known molding methods according to the type of metal, for example, die casting. What was manufactured by the method can be used.
- the resin of the resin molded body used in the composite molded body of the present invention includes thermoplastic elastomers in addition to thermoplastic resins and thermosetting resins.
- the thermoplastic resin can be appropriately selected from known thermoplastic resins depending on the application.
- 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
- thermosetting resin can be appropriately selected from known thermosetting resins depending on the application.
- urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin, polyurethane, and vinyl urethane can be mentioned.
- 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.
- thermoplastic resins, thermosetting resins, and thermoplastic elastomers can be blended with known fibrous fillers.
- known fibrous fillers include carbon fibers, inorganic fibers, metal fibers, and organic fibers. Carbon fibers are well known, and PAN, pitch, rayon, lignin and the like can be used.
- inorganic fibers include glass fibers, basalt fibers, silica fibers, silica / alumina fibers, zirconia fibers, boron nitride fibers, and silicon nitride fibers.
- the metal fiber include fibers made of stainless steel, aluminum, copper and the like.
- organic fibers examples include polyamide fibers (fully aromatic polyamide fibers, semi-aromatic polyamide fibers in which one of diamine and dicarboxylic acid is an aromatic compound, aliphatic polyamide fibers), polyvinyl alcohol fibers, acrylic fibers, polyolefin fibers, Synthetic fibers such as polyoxymethylene fibers, polytetrafluoroethylene fibers, polyester fibers (including wholly aromatic polyester fibers), polyphenylene sulfide fibers, polyimide fibers, liquid crystal polyester fibers, natural fibers (cellulosic fibers, etc.) and regenerated cellulose ( Rayon) fiber or the like can be used.
- polyamide fibers fully aromatic polyamide fibers, semi-aromatic polyamide fibers in which one of diamine and dicarboxylic acid is an aromatic compound
- aliphatic polyamide fibers examples include polyvinyl alcohol fibers, acrylic fibers, polyolefin fibers, Synthetic fibers such as polyoxymethylene fibers, polytetra
- these fibrous fillers those having a fiber diameter in the range of 3 to 60 ⁇ m can be used, and among these, for example, the width of the marking pattern formed on the joint surface 11 of the metal molded body 10 ( It is preferable to use one having a fiber diameter smaller than the size of the opening of the pore or the width of the groove.
- the fiber diameter is more desirably 5 to 30 ⁇ m, and further desirably 7 to 20 ⁇ m.
- a fibrous filler having a fiber diameter smaller than the width of the marking pattern is used, a composite molded body in which a part of the fibrous filler is stuck in the marking pattern of the metal molded body is obtained. This is preferable because the bonding strength between the molded body and the resin molded body is increased.
- the weight average fiber length contained in the resin molded product is preferably 0.1 to 5.0 mm, more preferably 0.1 to 4.0 mm, still more preferably 0.2 to 3.0 mm, and most preferably 0. It is preferable to use a raw material having a length that can be adjusted to 5 to 2.5 mm.
- 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. More preferably, it is 25 to 200 parts by mass, and even more preferably 45 to 150 parts by mass.
- a known laser can be used.
- YVO4 laser, YAG laser, fiber laser, excimer laser, ultraviolet laser, carbon dioxide gas laser, semiconductor laser, glass laser, ruby laser, He—Ne laser, nitrogen laser, chelate laser, and dye laser can be used.
- Laser irradiation conditions such as wavelength, beam diameter, pore spacing, frequency, etc., depend on the size, mass, type, and required bonding strength of the metal molded body and resin molded body to be bonded. It can be determined as appropriate.
- Example 1 The joint surface 12 of the metal molded body (aluminum: A5052) shown in FIG. 5 was irradiated with laser under the conditions shown in Table 1 to form 372 circular regions 30a shown in FIG.
- the laser oscillator used was a fiber laser (IPG YLP-1-50-30-30RA).
- FIG. 6A is an SEM photograph (100 times) of a plane of the metal molded body used in Example 1
- FIG. 6B is an enlarged photograph (200 times) of FIG. ) Is an SEM photograph (100 times) of the cross section in the thickness direction of FIG.
- insert molding was performed by the following method to obtain a composite molded body of Example 1.
- Comparative Example 1 The joint surface 12 of the metal molded body (aluminum: A5052) shown in FIG. 5 was irradiated with laser under the conditions shown in Table 1 to form a groove composed of a plurality of bent lines in the state shown in FIG. .
- the laser oscillator used was a fiber laser (IPG YLP-1-50-30-30RA). After forming the groove
- Comparative Example 2 The joint surface 12 of the metal molded body (aluminum: A5052) shown in FIG. 5 was irradiated with laser under the conditions shown in Table 1 to form a groove composed of a plurality of bent lines in the state shown in FIG. .
- the laser oscillator used was a fiber laser (IPG YLP-1-50-30-30RA). After forming the groove
- Example 1 since the irradiation distance of one scan is shorter than that of Comparative Examples 1 and 2, the diffusion of heat is suppressed, so that the groove depth per scan can be increased. For this reason, when Example 1 is compared with Comparative Example 1, it can be confirmed that Example 1 can shorten the total scan time, and a composite molded body having a higher bonding strength than Comparative Example 1 was obtained. Moreover, when Example 1 and Comparative Example 2 are compared, it can be confirmed that a composite molded body having a bonding strength three times or higher was obtained when the same total scan time was obtained. Therefore, by applying the manufacturing method of the present invention, the efficiency of laser processing (processing amount per hour) can be greatly improved.
Abstract
Description
しかしながら、金属成形体と樹脂成形体を工業的に有利な方法で、かつ高い接合強度で接合一体化できる技術は実用化されていない。
さらにクロス方向へのレーザースキャンにより十分な表面粗し処理ができることから、接合強度は高くできることが考えられるが、表面粗さ状態が均一にならず、金属と樹脂との接合部分の強度の方向性が安定しないおそれがあるという問題がある。
例えば、1つの接合体はX軸方向への剪断力や引張強度が最も高いが、他の接合体は、X軸方向とは異なるY軸方向への剪断力や引張強度が最も高く、さらに別の接合体は、X軸およびY軸方向とは異なるZ軸方向への剪断力や引張強度が最も高くなるという問題が発生するおそれがある。
製品によっては(例えば、一方向への回転体部品や一方向への往復運動部品)、特定方向への高い接合強度を有する金属と樹脂の複合体が求められる場合があるが、特許第4020957号公報、特開2010-167475号公報の発明では前記の要望には十分に応えることができない。
実施形態1~3では、金属長尺コイル表面にレーザー照射して凹凸を形成することが記載されている。そして、段落番号10では、金属長尺コイル表面をストライプ状や梨地状に荒らすこと、段落番号19では、金属長尺コイル表面をストライプ状、点線状、波線状、ローレット状、梨地状に荒らすることが記載されている。
しかし、段落番号21、22の発明の効果に記載されているとおり、レーザー照射をする目的は、金属表面に微細で不規則な凹凸を形成し、それによりアンカー効果を高めるためである。特に処理対象が金属長尺コイルであることから、どのような凹凸を形成した場合でも、必然的に微細で不規則な凹凸になるものと考えられる。
よって、特開平10-294024号公報の発明は、特許第4020957号公報、特開2010-167475号公報の発明のようにクロス方向にレーザー照射して表面に微細な凹凸を形成する発明と同じ技術的思想を開示しているものである。
金属成形体と樹脂成形体が接合された複合成形体の製造方法であって、
前記金属成形体の接合面に対して、レーザースポット径10~200μmの範囲のレーザー光を照射して溝を形成し、直径が20~1000μmの円形またはそれと同面積範囲の一つの領域を形成する工程であり、1スキャンによりレーザー照射の開始点と終点が繋がるようにして溝を形成し、これを複数スキャン繰り返して溝で囲まれた一つの領域を形成する第1工程、
前記第1工程を繰り返して、溝で囲まれた複数の領域を形成する第2工程、
前記溝で囲まれた領域が形成された金属成形体の接合面を含む部分を金型内に配置して、前記樹脂成形体となる樹脂インサート成形する第3工程を有している、複合成形体の製造方法を提供する。
図2(a)は、円柱(丸棒)の金属成形体10と円柱の樹脂成形体20が、曲面同士で接合一体化された複合成形体1の厚さ(直径)方向の断面図である。
図1および図2の複合成形体1は、以下の第1工程、第2工程および第3工程を経て製造することができる。
第1工程では、図3の平面図と部分拡大図に示すように、接合一体化される前の金属成形体10の接合面に対して、レーザースポット径(d)が10~200μmの範囲のレーザー光を照射して溝31を形成し、直径(D)が20~1000μmの円形またはそれと同面積範囲の一つの領域を形成する。
さらに第1工程では、1スキャンによりレーザー照射の開始点と終点が繋がるようにして溝31を形成し、これを同じ溝31が形成されるように複数スキャン繰り返して、溝31で囲まれ、溝31の内側に凸部32を有する一つの領域(円形領域)30を形成する。
溝31は、図3の部分拡大図に示すように、1スキャンによりレーザー照射の開始点と終点が繋がるようにして形成する。即ち、周方向に隣接するレーザースポット同士が互いに重複するか、または接触するようにしてレーザー照射する。
続いて2回目のスキャンにおいても、1回目のスキャンと同様にして同じ溝31上を複数回スキャンする。複数回スキャンすることで溝31の深さ(即ち、凸部32の高さ)を調整する。
円形以外の領域にした場合には、直径(D)が20~1000μmの円形またはそれと同面積範囲の一つの領域になるようにする。
1つの領域の大きさは、直径(D)が20~1000μmの円形またはそれと同面積範囲であり、好ましくは直径(D)が20~500μmの円形またはそれと同面積範囲であり、より好ましくは直径(D)が20~300μmの円形またはそれと同面積範囲である。
1スキャンの照射距離は100~100,000μmが好ましく、100~10,000μmがより好ましく、100~1000μmがさらに好ましい。このように1スキャンの照射距離を短くすることで、スキャン間の熱の拡散と金属温度の低下を抑えることができるため、レーザー加工の効率(時間当たりの加工量)が良くなる。
1スキャンのレーザー光照射で形成される溝の深さは5~300μmが好ましく、10~300μmがより好ましい。
全スキャン後の溝の深さは10~600μmが好ましく、10~300μmがより好ましい。
出力は4~4000Wが好ましい。
波長は300~1200nmが好ましく、500~1200nmがより好ましい。
1スキャンのパルス幅(1スキャンのレーザー光の照射時間)は1~10,000nsecが好ましい。
周波数は1~100kHzが好ましい。
焦点位置は-10~+10mmが好ましく、-6~+6mmがより好ましい。
加工速度は10~10,000mm/secが好ましく、100~10,000mm/secがより好ましく、300~10,000mm/secがさらに好ましい。
スキャン回数は1~30回が好ましい。
第2工程では、第1工程を繰り返して、金属成形体10の接合面12に対して、図4(a)~(g)で示される複数の領域30(30a~30g)を形成する。
図4(a)~(e)では、接合面12の全面に領域30(30a~30e)が形成されており、図4(f)、(g)では、接合面12の一部面に領域30(30f、30g)が形成されている。
図4(f)では、複数の円形領域30fは、接合面12の辺12a側の円形領域30fの形成密度が高くなり、反対側の辺12b側の円形領域30fの形成密度が低くなるように形成されている。このようにして接合面12において円形領域30fを均等配置せず、一部面に偏在させるように成形することができる。
図1で示す複合成形体1が、接合面12に図4(f)に示された複数の円形領域30fが形成されたものであるとき、円形領域30fが辺12a側に密になるように形成されているため、複合成形体1が図4(f)の矢印方向に引っ張られるときの抗力が大きくなり、金属成形体10と樹脂成形体20との接合強度が高められる。
なお、図4(g)とは逆に、接合面12の中央部にのみ複数の円形領域30gが形成され、周囲には円形領域30gが形成されないようにしてもよい。
第3工程にて、複数の領域30が形成された金属成形体10の接合面12を含む部分を金型内に配置して、樹脂成形体20となる樹脂を使用してインサート成形して、複合成形体1を得る。
このインサート成形工程によって、図1に示すように、領域30(溝31と突起32)の溝31内に樹脂が入り込んだ状態の複合成形体1が得られる。
このように金属成形体10が領域30(溝31と突起32)を有していることから、金属成形体10と樹脂成形体20との接触面積が増大されると共に、溝31内に樹脂が入り込むことによるアンカー効果によって、接合強度が高められる。
さらに、例えば図4(a)~(g)に示すように、領域30の配置状態を調整したり、形成パターンを調整したりすることで、所望方向への引張強度や曲げ強度が高められた複合成形体を得ることができるようなる。
本発明の複合成形体で使用する金属成形体の成形方法は特に制限されるものではなく、金属の種類に応じて公知の各種成形法を適用して製造することができものであり、例えばダイカスト法で製造したものを使用することができる。
公知の繊維状充填材としては、炭素繊維、無機繊維、金属繊維、有機繊維等を挙げることができる。
炭素繊維は周知のものであり、PAN系、ピッチ系、レーヨン系、リグニン系等のものを用いることができる。
無機繊維としては、ガラス繊維、玄武岩繊維、シリカ繊維、シリカ・アルミナ繊維、ジルコニア繊維、窒化ホウ素繊維、窒化ケイ素繊維等を挙げることができる。
金属繊維としては、ステンレス、アルミニウム、銅等からなる繊維を挙げることができる。
有機繊維としては、ポリアミド繊維(全芳香族ポリアミド繊維、ジアミンとジカルボン酸のいずれか一方が芳香族化合物である半芳香族ポリアミド繊維、脂肪族ポリアミド繊維)、ポリビニルアルコール繊維、アクリル繊維、ポリオレフィン繊維、ポリオキシメチレン繊維、ポリテトラフルオロエチレン繊維、ポリエステル繊維(全芳香族ポリエステル繊維を含む)、ポリフェニレンスルフィド繊維、ポリイミド繊維、液晶ポリエステル繊維などの合成繊維や天然繊維(セルロース系繊維など)や再生セルロース(レーヨン)繊維などを用いることができる。
このようなマーキングパターンの幅より小さな繊維径の繊維状充填材を使用したときには、金属成形体のマーキングパターン内に繊維状充填材の一部が張り込んだ状態の複合成形体が得られ、金属成形体と樹脂成形体の接合強度が高められるので好ましい。
さらにこれらの繊維状充填材は、樹脂成形体の機械的強度を高め、金属成形体との機械的強度差を小さくすることで金属成形体と樹脂成形体との接合強度を高めるため、成形後の樹脂成形体中に含まれる重量平均繊維長が、好ましくは0.1~5.0mm、より好ましくは0.1~4.0mm、さらに好ましくは0.2~3.0mm、もっとも好ましくは0.5~2.5mmにできるような長さのものを製造原料として使用することが好ましい。
熱可塑性樹脂、熱硬化性樹脂、熱可塑性エラストマー100質量部に対する繊維状充填材の配合量は5~250質量部が好ましい。より望ましくは、25~200質量部、さらに望ましくは45~150質量部である。
図5に示す金属成形体(アルミニウム:A5052)の接合面12に対して、表1に示す条件でレーザー照射して、図4(a)に示す372個の円形領域30aを形成した。なお、レーザー発振器はファイバーレーザー(IPG製 YLP-1-50-30-30RA)を使用した。
上記のようにして金属成形体に円形領域を形成した後、下記の方法でインサート成形して、実施例1の複合成形体を得た。
図5に示す金属成形体(アルミニウム:A5052)の接合面12に対して、表1に示す条件でレーザー照射して、図7に示すような状態の複数回折れ曲がった直線からなる溝を形成した。なお、レーザー発振器はファイバーレーザー(IPG製 YLP-1-50-30-30RA)を使用した。
上記のようにして金属成形体に直線からなる溝を形成した後、下記の方法でインサート成形して、比較例1の複合成形体を得た。
図5に示す金属成形体(アルミニウム:A5052)の接合面12に対して、表1に示す条件でレーザー照射して、図7に示すような状態の複数回折れ曲がった直線からなる溝を形成した。なお、レーザー発振器はファイバーレーザー(IPG製 YLP-1-50-30-30RA)を使用した。
上記のようにして金属成形体に直線からなる溝を形成した後、下記の方法でインサート成形して、比較例2の複合成形体を得た。
樹脂:GF60%強化PA66樹脂(プラストロンPA66-GF60-01(L7):ダイセルポリマー(株)製),ガラス繊維の繊維長:11mm
樹脂温度:320℃
金型温度:100℃
射出成形機:ファナック社製FANUC ROBOSHOT S2000i-100B
実施例1、比較例1、2の複合成形体を用い、引張試験を行って接合強度を評価した。結果を表1に示す。
なお、複合成形体の樹脂成形体中のガラス繊維の繊維長(重量平均繊維長)は0.85mmであった。平均繊維長は、成形品から約3gの試料を切出し、650℃で加熱・灰化させてガラス繊維を取り出した。取り出した繊維の一部(500本)から重量平均繊維長を求めた。計算式は、特開2006-274061号公報の〔0044〕、〔0045〕を使用した。
引張試験は、金属成形体側を固定した状態で、金属成形体と樹脂成形体が破断するまで図8に示すX1方向に引っ張った場合の最大荷重を測定した。
<引張試験条件>
試験機:オリエンテック社製テンシロン(UCT-1T)
引張速度:5mm/min
チャック間距離:50mm
このため、実施例1と比較例1を比べると、実施例1は合計スキャン時間を短くでき、比較例1よりも高い接合強度の複合成形体が得られたことが確認できる。
また実施例1と比較例2を比べると、同じ合計スキャン時間であるときには、3倍以上高い接合強度の複合成形体が得られたことが確認できる。
よって、本発明の製造方法を適用することで、レーザー加工の効率(時間当たりの加工量)を大きく向上させることができるようになる。
10 金属成形体
12 接合面
20 樹脂成形体
Claims (7)
- 金属成形体と樹脂成形体が接合された複合成形体の製造方法であって、
前記金属成形体の接合面に対して、レーザースポット径10~200μmの範囲のレーザー光を照射して溝を形成し、直径が20~1000μmの円形またはそれと同面積範囲の一つの領域を形成する工程であり、1スキャンによりレーザー照射の開始点と終点が繋がるようにして溝を形成し、これを複数スキャン繰り返して溝で囲まれた一つの領域を形成する第1工程、
前記第1工程を繰り返して、溝で囲まれた複数の領域を形成する第2工程、
前記溝で囲まれた領域が形成された金属成形体の接合面を含む部分を金型内に配置して、前記樹脂成形体となる樹脂インサート成形する第3工程を有している、複合成形体の製造方法。 - 前記第1工程において溝で囲まれた一つの領域が、溝で形成された円形、楕円形、三角形、四角形、五角形以上の多角形および不定形から選ばれる領域である、請求項1記載の複合成形体の製造方法。
- 前記第2工程が、それぞれが独立した複数の領域を形成する工程である、請求項1または2記載の複合成形体の製造方法。
- 前記第2工程が、複数の領域の隣接する領域同士の全部または一部が重複して形成する工程である、請求項1または2記載の複合成形体の製造方法。
- 前記第2工程が、前記金属成形体の接合面の全体に複数の領域を形成する工程である、請求項1または2記載の複合成形体の製造方法。
- 前記第2工程が、前記金属成形体の接合面の一部に複数の領域を形成する工程である、請求項1または2記載の複合成形体の製造方法。
- 前記金属成形体の接合面が平面または曲面である、請求項1~6のいずれか1項記載の複後成形体の製造方法。
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WO2021001253A1 (de) * | 2019-07-02 | 2021-01-07 | Kolektor Group D.O.O. | Elektrische oder elektronische baugruppe sowie verfahren zur herstellung eines elektrischen oder elektronischen bauteils |
CN114269540A (zh) * | 2019-07-02 | 2022-04-01 | 科莱克特集团公司 | 电气或电子构件以及制造电气或电子构件的方法 |
US20220118662A1 (en) * | 2019-07-02 | 2022-04-21 | Kolektor Group D.O.O. | Electrical or electronic assembly and method for producing an electrical or electronic component |
US11752674B2 (en) | 2019-07-02 | 2023-09-12 | Kolektor Mobility d.o.o. | Electrical or electronic assembly and method for producing an electrical or electronic component |
Also Published As
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TW201446463A (zh) | 2014-12-16 |
CN110116275A (zh) | 2019-08-13 |
KR20150139511A (ko) | 2015-12-11 |
CN110116275B (zh) | 2021-05-25 |
CN105102201B (zh) | 2019-01-08 |
TW201825220A (zh) | 2018-07-16 |
JP5932700B2 (ja) | 2016-06-08 |
JP2014193569A (ja) | 2014-10-09 |
TWI676518B (zh) | 2019-11-11 |
CN105102201A (zh) | 2015-11-25 |
TWI616303B (zh) | 2018-03-01 |
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