WO2022172398A1 - 接合体及び接合体の製造方法 - Google Patents

接合体及び接合体の製造方法 Download PDF

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Publication number
WO2022172398A1
WO2022172398A1 PCT/JP2021/005260 JP2021005260W WO2022172398A1 WO 2022172398 A1 WO2022172398 A1 WO 2022172398A1 JP 2021005260 W JP2021005260 W JP 2021005260W WO 2022172398 A1 WO2022172398 A1 WO 2022172398A1
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WO
WIPO (PCT)
Prior art keywords
joint surface
metal
joined body
synthetic resin
anchor
Prior art date
Application number
PCT/JP2021/005260
Other languages
English (en)
French (fr)
Inventor
聖一 斎
Original Assignee
睦月電機株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 睦月電機株式会社 filed Critical 睦月電機株式会社
Priority to JP2021529353A priority Critical patent/JP7005081B1/ja
Priority to PCT/JP2021/005260 priority patent/WO2022172398A1/ja
Priority to CN202180002137.9A priority patent/CN115250614A/zh
Priority to EP21805828.7A priority patent/EP4070910A4/en
Publication of WO2022172398A1 publication Critical patent/WO2022172398A1/ja

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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
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • 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
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/355—Texturing
    • 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
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/3568—Modifying rugosity
    • B23K26/3584—Increasing rugosity, e.g. roughening
    • 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
    • B29C65/44—Joining a heated non plastics element to a plastics element
    • B29C65/46—Joining a heated non plastics element to a plastics element heated by induction
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835—Heat curing adhesives
    • 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
    • B29C66/024—Thermal pre-treatments
    • B29C66/0246—Cutting or perforating, e.g. burning away by using a laser or using hot air
    • 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
    • B29C66/05—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
    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30321—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of protrusions belonging to at least one of the parts to be joined
    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30321—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of protrusions belonging to at least one of the parts to be joined
    • B29C66/30322—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of protrusions belonging to at least one of the parts to be joined in the form of rugosity
    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • 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
    • B29C66/73—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
    • 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
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • 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
    • 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
    • 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
    • B23K2103/26—Alloys of Nickel and Cobalt and Chromium
    • 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
    • B29C66/73—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
    • B29C66/7394—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 thermoset

Definitions

  • the present invention relates to a joined body and a method for manufacturing the joined body.
  • an uneven anchor portion is sometimes formed on the surface of one of the members in order to increase the joint strength.
  • Patent Document 1 metal powder is adhered to the joint surface of one member, and then laser cladding is applied to the surface to which the metal powder is adhered, thereby joining substantially spherical metal powder to the joint surface.
  • a method of forming the anchor portion has been proposed.
  • the joint strength of the anchor part to the joint surface must be maintained while maintaining a shape that facilitates the anchor part (metal powder) adhering to the joint surface to exhibit the anchor effect. It is important to increase
  • Patent Document 1 if an attempt is made to improve the adhesive strength of the anchor portion to the joint surface, the metal powder melts and deforms into a shape that makes it difficult to exhibit the anchor effect. Further, if an attempt is made to maintain a shape that facilitates the anchoring effect, the metal powder will be less likely to melt, and the adhesive strength of the anchor portion to the joint surface will be reduced.
  • the present invention has been made in view of the above points, and aims to improve the bonding strength of a bonded body by forming an anchor portion having a shape that facilitates the anchoring effect and having a high bonding strength with respect to the bonding surface. aim.
  • a bonded body comprising a first member having a first bonding surface provided with an anchor portion and a second member having a second bonding surface, wherein the second bonding surface is bonded to the first bonding surface , the anchor part protrudes from the first joint surface and includes a plurality of protrusions arranged along a first direction, the plurality of protrusions extending in a second direction perpendicular to the first direction; and has an undercut portion on both sides of the first so that the cross-sectional shape along the first direction including the top portion has the longest length along the first direction on the first joint surface side
  • a bonded body having a shape that widens in the first direction as it approaches the bonding surface.
  • the plurality of protrusions include a protruding streak portion that protrudes from the first joint surface and extends along the first direction, and a protruding streak portion that is provided on an upper portion of the protruding streak portion and spreads in the second direction from the protruding streak portion.
  • the second joint surface of the second member is joined to the first joint surface of the first member provided with the anchor portion, the anchor having a plurality of projections projecting from the first joint surface and after the anchor forming step
  • the second member is pressurized while being in contact with the plurality of protrusions to cause the plurality of protrusions to enter the second member, thereby forming the first bonding surface.
  • a bonding step of bringing the second bonding surface into contact with the second bonding surface, and the anchor forming step includes irradiating the first bonding surface with a pulsed laser beam while scanning the first bonding surface in the first direction.
  • a method of manufacturing a joined body wherein a plurality of protrusions are arranged along the first direction so as to extend in the first direction toward the first joint surface so as to be elongated.
  • an anchor portion having a shape that facilitates the anchoring effect and having a high bonding strength with respect to the bonding surface, thereby obtaining a bonded body having a high bonding strength.
  • FIG. 1 is a cross-sectional view showing a schematic configuration of a joined body according to a first embodiment of the present invention
  • FIG. 2 is a plan view showing a schematic configuration of a first joint surface of a first member constituting the joined body of FIG. 1
  • FIG. 4 is a diagram showing a softening step of the manufacturing method of the joined body according to the first embodiment of the present invention
  • FIG. 4 is a diagram showing a pressurizing step of the method for manufacturing a joined body according to the first embodiment of the present invention
  • FIG. 11 is a diagram showing a softening step of a method for manufacturing a joined body according to the second embodiment of the present invention
  • FIG. 11 is a diagram showing a pressurizing step of a method for manufacturing a joined body according to the second embodiment of the present invention; SEM photograph of a metal joint surface of a metal member in an example of the present invention SEM photograph of a cross section of a metal member cut in a first direction in an example of the present invention SEM photograph of a cross section of the metal member cut in the second direction in the example of the present invention
  • the joined body 10 includes a first member (hereinafter sometimes referred to as “metal member”) 30 made of metal and a second member (hereinafter referred to as “synthetic resin member”) made of thermoplastic resin. ) 20.
  • the metal member 30 has a first joint surface (hereinafter sometimes referred to as “metal joint surface”) 32 on which an anchor portion 34 is formed.
  • the synthetic resin member 20 has a second joint surface (hereinafter sometimes referred to as a “resin joint surface”) 22 on its surface.
  • the bonded body 10 is obtained by bonding the resin bonding surface 22 to the metal bonding surface 32 to integrate the metal member 30 and the synthetic resin member 20 .
  • the synthetic resin member 20 is a member obtained by molding a thermoplastic resin into a predetermined shape such as a block, plate, or line. Further, the synthetic resin member 20 may be a thermoplastic resin coating film or an adhesive layer made of a thermoplastic resin adhesive. Specific examples of the thermoplastic resin forming the synthetic resin member 20 include polypropylene resin (PP resin), polyacetal resin (POM resin), polyphenylene sulfide resin (PPS resin), polyetheretherketone resin (PEEK), and acrylonitrile.
  • PP resin polypropylene resin
  • POM resin polyacetal resin
  • PPS resin polyphenylene sulfide resin
  • PEEK polyetheretherketone resin
  • ABS resin polyethylene resin
  • PBT resin polybutylene terephthalate resin
  • PA resin polyamide resin
  • PA66 nylon 66
  • LCP resin liquid crystal polymer
  • Modified polyphenylene ether resin modified PPE
  • reactor type soft polypropylene resin metalocene reactor type TPO resin
  • perfluoroalkoxy fluororesin PFA
  • ETFE ethylene/tetrafluoroethylene copolymer
  • the synthetic resin member 20 is a carbon fiber reinforced thermoplastic resin (CFRTP) in which carbon fiber is blended with the thermoplastic resin as described above, a reinforcing material such as glass fiber, talc, etc. in the thermoplastic resin as described above.
  • CFRTP carbon fiber reinforced thermoplastic resin
  • a flame retardant material, an anti-deterioration agent, an elastomer component, or the like may be added.
  • the metal member 30 is a member obtained by molding metal into a predetermined shape such as a block, plate, or line.
  • the metal forming the metal member 30 is not particularly limited, and various metals can be used.
  • copper (Cu), iron (Fe), aluminum (Al), titanium (Ti), nickel (Ni), chromium (Cr), or the like can be used as the metal forming the metal member 30 .
  • the metal member 30 may be made of an alloy of two or more metals such as a copper alloy, an iron alloy (steel material), an aluminum alloy, stainless steel, a titanium alloy, a nickel alloy, or a chromium alloy.
  • the metal member 30 preferably has higher hardness than the synthetic resin member 20 at room temperature (25°C). Moreover, when joining the metal member 30 and the synthetic resin member 20 , it is preferable that the hardness of the metal member 30 is higher than that of the synthetic resin member 20 . When the metal member 30 and the synthetic resin member 20 are joined together, the hardness of the metal member 30 is higher than that of the synthetic resin member 20, and the hardness of the synthetic resin member 20 becomes higher than that of the metal member 30 at room temperature after joining. good too.
  • the hardness at room temperature is the Vickers hardness measured in accordance with JIS Z 2244, and when the metal member 30 and the synthetic resin member 20 are joined together, the metal member 30 and the synthetic resin member 20 are exposed to a high temperature. In some cases, hardness is high temperature Vickers hardness measured according to JIS Z 2252.
  • the shape of the metal member 30 can be a desired shape depending on the application.
  • An arbitrary method can be applied to the forming method of the metal member 30. Casting in which a molten metal or the like is poured into a mold of a desired shape, cutting using a machine tool or the like, punching using a press machine or the like is used. may
  • the metal member 30 may have an oxide film (metal oxide) formed on the metal joint surface 32 and the anchor portion 34 to be described later.
  • the oxide film may be a native oxide film naturally formed on the surface of the metal.
  • the oxide film may be formed on the surface of the metal member 30 by surface treatment with an oxidizing agent, electrolytic treatment by anodization, plasma oxidation treatment, heat oxidation treatment in an oxygen-containing gas, or the like.
  • the oxide film may be formed on the surface of the metal member 30 by rapidly heating the surface of the metal member 30 in an oxygen-containing gas atmosphere such as air. It is preferable that the temperature rise of the surface of the metal member 30 per minute during rapid heating is equal to or higher than the melting point temperature of the metal forming the metal member 30 . By rapidly heating the surface of the metal member 30 in this manner, a dense oxide film can be formed on the surface of the metal member 30 . Moreover, by rapidly heating the surface of the metal member 30, microcracks are generated on the surface of the oxide film, and the bonding area with the synthetic resin member 20 increases.
  • the surface of the metal member 30 can be rapidly heated by various methods such as laser heating, induction heating, or resistance heating. It is preferable to form an oxide film by heating the surface of the metal member 30 by irradiating with .
  • metal joint surface 32 of the metal member 30 is roughened and provided with an anchor portion 34 .
  • Anchor portion 34 The anchor portion 34 formed on the metal joint surface 32 has a plurality of protrusions 35 protruding from the metal joint surface 32, as shown in FIGS.
  • the plurality of protrusions 35 are provided side by side along a predetermined direction (hereinafter referred to as the first direction) X. As shown in FIG.
  • five anchor portions 34 are provided on the metal joint surface 32 at intervals in a direction Y perpendicular to the first direction X (hereinafter, this direction is the second direction).
  • one anchor portion 34 may be provided on the metal joint surface 32 , or a plurality of anchor portions 34 may be provided on the metal joint surface 32 at intervals in the second direction 2 .
  • one anchor portion 34 may be provided parallel to the other anchor portions 34 as shown in FIG. may be provided so as to incline.
  • Each protrusion 35 that constitutes the anchor portion 34 includes a protruding portion 35a protruding from the first joint surface 32 and an expansion portion 35b provided on the upper portion of the protruding portion 35a.
  • the ridge portion 35a has a narrow ridge shape extending in the first direction X.
  • the protruding line portion 35a may be connected to the protruding line portion 35a of the protrusion 35 adjacent in the first direction X.
  • the ridges 35a may be connected continuously so as to connect all the protrusions 35 that constitute the anchor portion 34, and some of the ridges 35a may be connected to each other.
  • the protruding streak portion 35a of the projection 35 adjacent in the one direction X may not be connected, and the protruding streak portion 35a may be divided in the middle of the first direction X.
  • the expanded portion 35b provided on the upper portion of the protruding portion 35a has a shape that expands in both the second direction Y from the protruding portion 35a.
  • each projection 35 is narrowed in the second direction Y at the protruding streak portion 35a provided below the expansion portion 35b, and undercut portions 35c are provided on both sides of the projection 35 in the second direction Y.
  • the inflatable portion 35b can have various shapes such as a substantially spherical body, a substantially ellipsoidal body, and a three-dimensional shape formed by connecting a plurality of substantially spherical bodies.
  • Each projection 35 constituting such an anchor portion 34 has a cross section along the first direction X including the top portion 35d of the projection 35 as shown in FIG.
  • the shape spreads in the first direction X as it approaches the metal joint surface 32 so that the length along the first direction X on the metal joint surface 32 side (that is, the contact portion with the metal joint surface 32) is the longest. It has a shape.
  • each protrusion 35 constituting the anchor portion 34 has a narrow base portion (portion on the metal joint surface 32 side) when viewed in the first direction X (see FIG. 4), and a base portion when viewed in the second direction Y. It extends in the first direction X (see FIG. 3).
  • the length from the metal joint surface 32 to the top portion 35d of the projection 35 is 50 ⁇ m to 200 ⁇ m, and the ridge portion 35a 10 ⁇ m to 100 ⁇ m in the second direction Y;
  • the distance between adjacent protrusions 35 can be 1 ⁇ m to 500 ⁇ m.
  • the length of the protruding portion 35 a in the first direction X may be equal to the length of the anchor portion 34 in the first direction X.
  • each projection 35 constituting the anchor portion 34 has a length Lx of the contact portion with the metal joint surface 32 in the cross section in the first direction as shown in FIG. It is longer than the length Ly of the contact portion with the metal joint surface 32 in a cross section along the second direction Y (hereinafter sometimes referred to as "second direction cross section").
  • each projection 35 constituting the anchor portion 34 has a shape in which the length in the first direction X gradually increases from the top portion 35d toward the metal joint surface 32 like the projection 35-1. Also, it has a thin constricted portion in the first direction X like the protrusion 35-2, and the metal joint surface 32 side of this constricted portion is elongated in the first direction X so that it is the longest in the first direction X. It may also have a flared shape (see FIG. 3).
  • a synthetic resin member 20 and a metal member 30 molded into a predetermined shape are prepared. Then, an anchor forming step is performed to form the anchor portion 34 on the metal joint surface 32 of the metal member 30 . After that, a bonding step is performed to bond the resin bonding surface 22 of the synthetic resin member 20 to the metal bonding surface 32 on which the anchor portion 34 is formed. As a result, the bonded body 10 in which the synthetic resin member 20 is bonded to the metal bonding surface 32 of the metal member 30 is obtained.
  • the anchor forming process and the bonding process will be described in detail below.
  • the metal bonding surface 32 of the metal member 30 to which the synthetic resin member 20 is bonded has a coefficient R represented by the following formula (1) of 0.1 or more. It is preferable to irradiate while moving (scanning) in the first direction X a pulsed laser beam that satisfies 0 or less.
  • h is the frequency of the laser light
  • k is the thermal diffusion coefficient (m 2 /sec) of the metal material forming the metal member 30
  • t is the pulse width of the laser light (sec)
  • v is the laser light. represents the scanning speed (m/sec) at which the is scanned.
  • the metal joint surface 32 When the metal joint surface 32 is irradiated with a pulsed laser beam having a coefficient R of 0.1 or more and 1.0 or less, when viewed from the first direction X, the root portion is narrowed, and when viewed from the second direction Y, the root portion becomes thin. are arranged side by side along the first direction X.
  • the anchor portion 34 is formed by irradiating the laser beam in the oxygen-containing gas as described above, a metal oxide is formed on the surface of the anchor portion 34 .
  • a pulsed laser beam is scanned in the first direction X at positions at predetermined intervals in the second direction Y, and the metal joint surface is scanned. 32 is irradiated.
  • a portion of the metal joint surface 32 where the anchor portion 34 is to be formed is irradiated with a laser beam to form the metal joint.
  • a pretreatment for removing impurities adhering to the surface 32 may be performed.
  • (5-2) Joining Step In the joining step, the metal member 30 and the synthetic resin member 20 are heated to soften the resin joint surface 22 side of the synthetic resin member 20, which is a softening step. After that, by pressing the synthetic resin member 20 against the metal member 30 while bringing the resin joint surface 22 into contact with the plurality of projections 35, the plurality of projections 35 enter the synthetic resin member 20, and the metal joint surface 32 becomes the resin joint surface. 22 is pressurized and brought into contact. As a result, the bonded body 10 in which the resin bonding surface 22 is bonded to the metal bonding surface 32 is obtained.
  • a bonding apparatus 50 as shown in FIGS. 5 and 6 is used to perform a softening step and a pressing step to manufacture the bonded body 10 .
  • the joining device 50 includes a stage 51 on which the metal member 30 is placed, a heating device 52 that induction-heats the metal member 30 placed on the stage 51, and a press that pressure-bonds the synthetic resin member 20 to the metal member 30. a device 53;
  • the metal member 30 is placed on the stage 51 so that the metal joint surface 32 provided with the anchor portion 34 faces the synthetic resin member 20 .
  • the heating device 52 includes an induction heating coil connected to a power supply (not shown), and when drive power is input from the power supply, the induction heating coil generates a magnetic field to heat the metal member 30 placed on the stage 51 .
  • the metal joint surface 32 of is induction-heated.
  • the press device 53 includes a rod 54 made of an insulating material such as ceramics, and a pressure member 55 that moves the rod 54 to press the synthetic resin member 20 against the metal joint surface 32 of the metal member 30 .
  • the rod 54 may be inserted into the hollow portion of the induction heating coil of the heating device 52 and arranged to face the synthetic resin member 20, as shown in FIG.
  • the pressurizing unit 55 includes a pneumatic cylinder controlled by an electropneumatic regulator, a spring pressurizer, or the like, and controls the speed at which the synthetic resin member 20 is moved together with the rod 54 and presses the synthetic resin member 20 against the metal member 30. It is preferable to be able to control the time pressure.
  • the stage In order to manufacture the bonded body 10 using the bonding apparatus 50, first, in an atmosphere in which gas exists, the stage is set so that the metal bonding surface 32 provided with the anchor portion 34 faces the synthetic resin member 20 to be set later. A metal member 30 is placed on 51 .
  • the synthetic resin member 20 is arranged so that the resin joint surface 22 faces the metal joint surface 32 of the metal member 30 placed on the stage 51 with a gap therebetween.
  • the distance between the metal joint surface 32 of the metal member 30 and the resin joint surface 22 of the synthetic resin member 20 is set to, for example, 0.001 mm to 10 mm.
  • the heating device 52 is arranged so as to face the metal bonding surface 32 of the metal member 30 with the synthetic resin member 20 interposed therebetween.
  • the heating device 52 is arranged above the synthetic resin member 20 and the synthetic resin member 20 is arranged between the heating device 52 and the metal member 30 .
  • a softening step is performed in which the resin bonding surface 22 of the synthetic resin member 20 is exposed to gas heated to the first temperature T1.
  • a driving power source is supplied to the heating device 52 to generate a magnetic field from an induction heating coil provided in the heating device 52 to heat the metal joint surface 32 of the metal member 30 .
  • the driving power supplied to the heating device 52, the position of the induction heating coil provided in the heating device 52, and the like are adjusted so that the metal joint surface 32 of the metal member 30 reaches the first temperature T1.
  • the heating device 52 performs a softening step of heating the metal joint surface 32 of the metal member 30 for a predetermined time S1 (for example, 1 to 10 seconds) to soften the resin joint surface 22 side of the synthetic resin member 20. After that, After completing the softening process, the process proceeds to the pressurizing process.
  • the heating device 52 stops heating the metal member 30 or reduces the amount of heating to continue the pressurization process, and the resin bonding surface 22, the metal bonding surface 32 and their surroundings (the metal member 30 and the synthetic resin member 20) is lowered (cooled) until it reaches the second temperature T2. Then, the synthetic resin member 20 and the metal member 30 are joined together at the second temperature T2.
  • the press device 53 moves the synthetic resin member 20 at a predetermined speed V to collide with the metal member 30 at a temperature lower than the first temperature T1 (second temperature T2).
  • the synthetic resin member 20 is strongly pressed against the metal member 30 at a position corresponding to the tip of the rod 54 and is pressed against the metal member 30 with a predetermined pressure P.
  • the plurality of protrusions 35 provided on the metal joint surface 32 enter the resin joint surface 22 side of the synthetic resin member 20, and the resin joint surface 22 contacts the metal joint surface 32 under pressure. is obtained.
  • the second step ends.
  • the first temperature T1 can be a temperature equal to or higher than the load deflection temperature Tf of the thermoplastic resin forming the synthetic resin member 20 when a load of 1.8 MPa is applied.
  • the synthetic resin member 20 is made of a thermoplastic resin mixed with a reinforcing material such as carbon fiber, glass fiber, or talc
  • a load of 1.8 MPa is applied to the thermoplastic resin constituting the synthetic resin member 20.
  • the deflection temperature under load Tf is the deflection temperature under load Tf of a thermoplastic resin containing no reinforcing material when a load of 1.8 MPa is applied.
  • the upper limit of the first temperature T1 can be set to a temperature lower than the decomposition temperature of the thermoplastic resin forming the synthetic resin member 20, that is, lower than the temperature at which the thermoplastic resin begins to vaporize.
  • the upper limit of the first temperature T1 may be 1000.degree.
  • the upper limit of the first temperature T1 can be set to a temperature 20° C. higher than the melting point Tm of the thermoplastic resin forming the synthetic resin member 20 .
  • the second temperature T2 may be any temperature lower than the first temperature T1, but should be equal to or higher than the load deflection temperature Tf of the thermoplastic resin constituting the synthetic resin member 20 when a load of 1.8 MPa is applied.
  • the second temperature T ⁇ b>2 is preferably lower than the melting point Tm of the thermoplastic resin forming the synthetic resin member 20 .
  • a temperature difference between the first temperature T1 and the second temperature T2 is preferably 1° C. or more and 20° C. or less.
  • the melting point Tm of a thermoplastic resin is a value measured at a temperature increase rate of 10°C per minute using a differential scanning calorimeter according to JIS K7121.
  • the melting points of typical thermoplastic resins are 168°C for polypropylene resin, 265°C for nylon 66, 232 to 267°C for polybutylene terephthalate resin, and 280°C for polyphenylene sulfide resin.
  • the deflection temperature under load Tf of the thermoplastic resin is the deflection temperature under load when a load of 1.8 MPa is applied, measured according to JIS K7191.
  • the load deflection temperature Tf of typical thermoplastic resins when a load of 1.8 MPa is applied is 57 to 65 ° C. for polypropylene resin, 66 to 68 ° C. for nylon 66, 58 ° C. for polybutylene terephthalate resin, and 58 ° C. for polyphenylene.
  • Sulfide resin is 105°C.
  • the softening step is preferably performed in an oxygen-containing gas such as air. That is, the metal bonding surface 32 and the resin bonding surface 22 are heated to the first temperature T1 in an oxygen-containing gas atmosphere, and the metal bonding surface 32 and the resin bonding surface 22 are heated to the first temperature T1 in the oxygen-containing gas. Exposure is preferred.
  • the resin bonding surface 22 of the synthetic resin member 20 reacts with oxygen contained in the oxygen-containing gas, thereby neutralizing basic or amphoteric oxides. As a result, a functional group that can be chemically bonded is generated on the resin bonding surface 22 of the synthetic resin member 20 .
  • the surface of the metal member 30 is oxidized and covered with an oxide film made of a metal oxide. and van der Waals forces and hydrogen bonds.
  • the functional group of the resin bonding surface 22 and the metal oxide of the metal member 30 are covalently bonded by a neutralization reaction (dehydration condensation). to form
  • Examples of functional groups generated on the resin bonding surface 22 include a carboxyl group (--COOH), a carbonyl group (--CO--), and a hydroxy group generated by oxidative decomposition of the thermoplastic resin forming the synthetic resin member 20. (—OH).
  • the thermoplastic resin constituting the synthetic resin member 20 contains a sulfur atom (hetero atom) such as polyphenylene sulfide resin (PPS)
  • the functional groups possessed by the resin bonding surface 22 are carboxyl groups, carbonyl groups, and hydroxy groups.
  • sulfone groups (--SO 3 H), sulfonyl groups (--SO 2 ⁇ ), sulfanyl groups (--SH), disulfide groups (--SS-- ) and the like may be included.
  • the resin bonding surface 22 has a carboxyl group (R—COOH) as a functional group
  • the metal member 30 is a divalent metal.
  • R is the main chain of the thermoplastic resin forming the synthetic resin member 20 and Me is the metal forming the metal member 30 .
  • the second temperature T2 is the same as the functional group of the resin bonding surface 22 of the synthetic resin member 20 and the metal formed on the metal bonding surface 32 of the metal member 30. It is preferably a temperature at which a covalent bond can be formed by a neutralization reaction with an oxide. Moreover, the second temperature T2 is preferably a temperature at which water generated by the neutralization reaction is removed from the reaction system. The second temperature T2 varies depending on the types of functional groups and metal oxides, so it is difficult to define unconditionally. more preferred.
  • the metal member 30 and the synthetic resin member 20 may be heated so that the entire metal member 30 and the synthetic resin member 20 reach the first temperature T1, but the resin bonding surface 22 may be heated to the first temperature T1.
  • the metal member 30 and the synthetic resin member 20 may be heated so that at least the metal joint surface 32 and the resin joint surface 22 reach the first temperature T1 by exposing them to the gas heated to the temperature T1.
  • the resin bonding surface 22 side of the synthetic resin member 20 is softened, making it easier for the protrusions 35 to enter the synthetic resin member 20 in the pressurizing step and suppressing deformation of the synthetic resin member 20 .
  • the pressure P when the synthetic resin member 20 is pressed against the metal member 30 is preferably a pressure equal to or higher than the compressive yield stress of the thermoplastic resin forming the synthetic resin member 20 . Since this pressure P varies depending on the thermoplastic resin that constitutes the synthetic resin member 20, it is difficult to define it unconditionally, but it is preferably 10 to 100 MPa.
  • the planar shape of the joining portion may be any shape such as a point shape, a linear shape, or a planar shape.
  • the synthetic resin member 20 may be pressed against the metal member 30 so that the entire anchor portion 34 provided on the metal joint surface 32 is pressurized.
  • the synthetic resin member 20 may be locally (spotwise) pressed against the metal member 30 as shown in FIG.
  • the temperatures of the synthetic resin member 20, the metal member 30 and their surroundings may be maintained at the second temperature T2.
  • the synthetic resin member 20 may be kept in contact with the metal member 30 under pressure until the temperatures of the synthetic resin member 20, the metal member 30 and their surroundings are cooled to a predetermined temperature or less.
  • the synthetic resin member 20 is applied to the metal member 30 until the temperatures of the synthetic resin member 20, the metal member 30 and their surroundings are cooled below the glass transition temperature Tg of the thermoplastic resin forming the synthetic resin member 20. It is preferable to contact them under pressure.
  • the synthetic resin member 20 molded in advance into a predetermined shape is heated and crimped to the metal member 30 has been described.
  • the synthetic resin member 20 may be joined to the metal member 30 by inserting it into a mold and injecting the melted synthetic resin material toward the metal joining surface 32 in the injection mold.
  • the undercut portions 35c are provided on both sides of the plurality of projections 35 constituting the anchor portion 34 in the second direction Y. Therefore, the synthetic resin member 20 and the metal member 30 It is possible to increase the bonding strength with.
  • the plurality of projections 35 are arranged in the first direction X as they approach the metal joint surface 32 so that the shape of the cross section in the first direction is the longest along the first direction X on the metal joint surface 32 side. It has an expansive shape. Therefore, while maintaining a shape that facilitates the anchor effect, the bonding strength of the plurality of projections 35 to the metal bonding surface 32 is increased, and the projections 35 themselves are less likely to be damaged during or after bonding the synthetic resin member 20. As a result, the bonding strength of the bonded body 10 can be improved.
  • the plurality of protrusions 35 constituting the anchor portion 34 are arranged side by side along the first direction X, a large number of protrusions 35 can be provided on the metal bonding surface 32 with appropriate intervals. The bonding strength of the bonded body 10 can be improved.
  • the bonding strength of the protrusions 35 to the metal bonding surface 32 can be further improved.
  • the protrusion 35 with respect to the metal joint surface 32 can further improve the bonding strength.
  • the plurality of projections 35 provided on the metal member 30 can be easily inserted into the synthetic resin member 20, and the plurality of projections 35 are less likely to be damaged. A high anchor effect can be obtained.
  • the functional group of the resin bonding surface 22 of the synthetic resin member 20 is bonded to the metal oxide of the anchor portion 34 by dipole interaction. do.
  • the functional groups of the resin bonding surface 22 form covalent bonds with the metal oxide through a neutralization reaction (dehydration condensation). Therefore, the bonding strength of the bonded body 10 can be improved.
  • grooves 23 extending along the first direction X are formed in the resin bonding surface 22 .
  • the grooves 23 are provided at positions corresponding to the plurality of projections 35 forming the anchor portions 34 provided on the metal member 30 .
  • a plurality of protrusions 35 provided on the metal bonding surface 32 are fitted into the grooves 23 in the bonding process, and the bonded body 100 is obtained.
  • filling member 24 it is preferable to perform a filling step of filling the third member (hereinafter also referred to as "filling member") 24 into the groove 23 provided on the resin bonding surface 22 .
  • Any material can be used as the material for the filling member 24, but it is preferable that the material has a lower hardness than the metal member 30 when the metal member 30 and the synthetic resin member 20 are joined together. It is more preferable to use a material that heat-hardens after joining the synthetic resin member 30 to the synthetic resin member 20 . It is preferable to use a thermosetting resin such as an epoxy resin or a phenol resin as the filling member 24 .
  • Such a joined body 100 of the second embodiment performs a softening step of softening the filling member 24 by heating the metal member 30 and the filling member 24 . After that, by pressing the synthetic resin member 20 against the metal member 30 while bringing the filling member 24 into contact with the plurality of projections 35, the plurality of projections 35 enter the filling member 24, and the metal joint surface 32 is brought into contact with the resin joint surface 22. A pressurizing step is performed to make the contact while pressurizing. As a result, the bonded body 100 in which the resin bonding surface 22 is bonded to the metal bonding surface 32 is obtained.
  • the synthetic resin member 20 can easily enter the joint process. can.
  • the plurality of protrusions 35 are less likely to slip out of the grooves 23, and the bonding strength of the bonded body 100 can be improved.
  • the metal member 30 having the anchor portion 34 formed thereon and the synthetic resin member 20 made of thermoplastic resin are joined together.
  • the present invention can also be applied when joining resin members or joining resin members made of resin.
  • the softening step of softening the resin bonding surface 22 side of the synthetic resin member 20 by heating is performed in manufacturing the bonded body 10.
  • the softening step may be performed by a method such as humidification instead of heating.
  • ⁇ Metal member SUS304 whose surface is heated to a melting point of SUS304 of 1450 ° C. or higher for 1 second by laser irradiation and subjected to oxidation and roughening treatment
  • ⁇ Synthetic resin member Susteel (registered trademark) SGX120 ⁇ Dimensions of metal members: 18 mm x 45 mm x 1.6 mm
  • the evaluation method is as follows.
  • a plurality of protrusions were arranged along the first direction X on the metal joint surface of the metal member of the example.
  • the plurality of protrusions provided on the metal joint surface has a shape in which the length in the first direction X increases as the cross section of the plurality of protrusions in the first direction approaches the metal joint surface from the top of the protrusion. had none.
  • the plurality of projections has a ridge portion and an expanded portion extending in both the second direction Y from the ridge portion on the upper portion thereof, and undersides on both sides of the projection in the second direction Y. A cut was provided.
  • the plurality of projections have a shape that widens in the first direction X toward the metal joint surface so that the cross-sectional shape along the first direction, including the apex, is the longest in the first direction X on the metal joint surface side.
  • the length of the contact portion with the metal joint surface in the cross section in the first direction was longer than the length of the contact portion with the metal joint surface 32 in the cross section in the second direction.
  • a plurality of concave grooves extending in the first direction X were provided on the metal joint surface of the metal member of Comparative Example 2 at intervals in the second direction Y, but no ridges or expanded portions were formed. rice field.

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  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

接合強度の高い接合体及びその製造方法を提供する。　本発明の接合体１０は、アンカ部３４が設けられた第１接合面３２を有する第１部材３０と、第２接合面２２を有する第２部材２０とを備え、第１接合面３２に第２接合面２２を接合した接合体１０において、アンカ部３４は、第１接合面３２から突出し、第１方向Ｘに沿って並んで設けられた複数の突起３５を備え、複数の突起３５は、第１方向Ｘに垂直な方向である第２方向Ｙの両側にアンダーカット部３５ｃを有し、頂部３５ｄを含む第１方向Ｘに沿った断面形状が、第１接合面３２側において第１方向Ｘに沿った長さが最も長くなるように、第１接合面３２に近づくほど第１方向Ｘに広がる形状をなしているものである。

Description

接合体及び接合体の製造方法
　本発明は、接合体及び接合体の製造方法に関する。
　同一あるいは異なる材料からなる部材同士を接合した接合体では、接合強度を高めるため、一方の部材の表面に凹凸形状のアンカ部を形成することがある。
　例えば、下記特許文献１では、一方の部材の接合面に金属粉末を付着させた後、金属粉末の付着した面にレーザクラッディングを施すことで、略球体の金属粉末を接合面に接合してアンカ部を形成する方法が提案されている。
　接合面にアンカ部を形成して高いアンカ効果を得るためには、接合面に付着するアンカ部（金属粉末）がアンカ効果を発揮しやすい形状を保持しつつ、接合面に対するアンカ部の接合強度を高めることが重要である。
　しかし、特許文献１の方法では、接合面に対するアンカ部の接着強度を向上させようとすると、金属粉末が溶融してアンカ効果を発揮しにくい形状に変形する。また、アンカ効果を発揮しやすい形状を保持しようとすると、金属粉末が溶融しにくくなり、接合面に対するアンカ部の接着強度が低くなる。
特開２０１６－１３０００３号公報
　本発明は、以上の点に鑑みてなされたものであり、アンカ効果を発揮しやすい形状を有するとともに、接合面に対する接合強度の高いアンカ部を形成し、接合体の接合強度を向上することを目的とする。
　本実施形態によれば、下記［１］～［１２］の態様が提供される。
　［１］アンカ部が設けられた第１接合面を有する第１部材と、第２接合面を有する第２部材とを備え、前記第１接合面に前記第２接合面を接合した接合体において、前記アンカ部は、前記第１接合面から突出し、第１方向に沿って並んで設けられた複数の突起を備え、前記複数の突起は、前記第１方向に垂直な方向である第２方向の両側にアンダーカット部を有し、頂部を含む前記第１方向に沿った断面形状が、前記第１接合面側において前記第１方向に沿った長さが最も長くなるように、前記第１接合面に近づくほど前記第１方向に広がる形状をなしている接合体。
　［２］前記複数の突起は、前記第１接合面から突出し前記第１方向に沿って延びる凸条部と、前記凸条部の上部に設けられ前記凸条部より前記第２方向へ広がった膨張部とを備える上記［１］に記載の接合体。
　［３］前記複数の突起の少なくとも一部は、前記第１方向に隣接する前記凸条部が繋がっている上記［２］に記載の接合体。
　［４］前記複数の突起の頂部を含む前記第１方向に沿った断面が、頂部から前記第１接合面に近づくほど前記第１方向の長さが長くなる形状をなしている上記［１］～［３］のいずれか１つに記載の接合体。
　［５］前記第２部材は前記第２接合面に前記第１方向に沿って延びる溝を備え、前記溝に前記複数の突起が嵌まっている上記［１］～［４］のいずれか１項に記載の接合体。
　［６］前記溝に充填された第３部材を備える上記［５］に記載の接合体。
　［７］前記第１部材が、前記第２部材より硬度が高い上記［１］～［４］のいずれか１つに記載の接合体。
　［８］前記アンカ部の表面に金属酸化物が設けられている上記［１］～［７］のいずれか１つに記載の接合体。
　［９］アンカ部が設けられた第１部材の第１接合面に第２部材の第２接合面を接合した接合体の製造方法において、前記第１接合面から突出し、複数の突起を有するアンカ部を形成するアンカ形成工程と、前記アンカ形成工程後、前記第２部材を前記複数の突起に接触させながら加圧して、前記複数の突起を前記第２部材に入り込ませて前記第１接合面を前記第２接合面に接触させる接合工程とを備え、前記アンカ形成工程は、前記第１接合面に対してパルスレーザ光を第１方向へ走査しながら照射することで、前記第１方向に垂直な方向である第２方向の両側にアンダーカット部を有し、頂部を含む前記第１方向に沿った断面形状が、前記第１接合面側において前記第１方向に沿った長さが最も長くなるように、前記第１接合面に近づくほど前記第１方向に広がる形状をなしている複数の突起を、前記第１方向に沿って並べて設ける接合体の製造方法。
　［１０］前記接合工程が、前記第２部材の前記第２接合面側を軟化させる軟化工程を備える上記［９］に記載の接合体の製造方法。
　［１１］前記第２接合面に前記第１方向に沿って延びる溝を形成する溝形成工程を備え、前記接合工程において前記溝に前記複数の突起を嵌める上記［９］に記載の接合体の製造方法。
　［１２］前記溝形成工程が、前記溝に第３部材を充填する工程を備え、前記接合工程が、前記第３部材を軟化させる軟化工程を備える上記［１１］に記載の接合体の製造方法。
　本発明では、アンカ効果を発揮しやすい形状を有するとともに、接合面に対する接合強度の高いアンカ部を形成することができ、接合強度の高い接合体が得られる。
本発明の第１実施形態に係る接合体の概略構成を示す断面図 図１の接合体を構成する第１部材の第１接合面の概略構成を示す平面図 図２のＡ－Ａ断面図 図２のＢ－Ｂ断面図 本発明の第１実施形態に係る接合体の製造方法の軟化工程を示す図 本発明の第１実施形態に係る接合体の製造方法の加圧工程を示す図 本発明の第２実施形態に係る接合体の製造方法の軟化工程を示す図 本発明の第２実施形態に係る接合体の製造方法の加圧工程を示す図 本発明の実施例における金属部材の金属接合面のＳＥＭ写真 本発明の実施例における金属部材を第１方向に切断した断面のＳＥＭ写真 本発明の実施例における金属部材を第２方向に切断した断面のＳＥＭ写真
（第１実施形態）
　以下、本発明の第１実施形態について図面を参照して説明する。なお、図面では、説明のために部材の大きさなどが誇張されて書かれている場合がある。
　（１）接合体１０
　まず、本実施形態の接合体１０について説明する。この接合体１０は、図１に示すように、金属からなる第１部材（以下、「金属部材」ということがもある）３０と、熱可塑性樹脂からなる第２部材（以下、「合成樹脂部材」ということもある）２０とを備える。金属部材３０はその表面にアンカ部３４が形成された第１接合面（以下、「金属接合面」ということがある）３２を有している。合成樹脂部材２０はその表面に第２接合面（以下、「樹脂接合面」ということがある）２２を有している。接合体１０は、金属接合面３２に樹脂接合面２２を接合して金属部材３０及び合成樹脂部材２０を一体化したものである。
　（２）合成樹脂部材２０
　合成樹脂部材２０は、熱可塑性樹脂をブロック状、板状、又は線状等の所定形状に成形した部材である。また、合成樹脂部材２０は、熱可塑性樹脂の塗膜や、熱可塑性樹脂製の接着剤からなる接着層であってもよい。合成樹脂部材２０を構成する熱可塑性樹脂として、具体例を挙げると、ポリプロピレン樹脂（ＰＰ樹脂）、ポリアセタール樹脂（ＰＯＭ樹脂）、ポリフェニレンサルファイド樹脂（ＰＰＳ樹脂）、ポリエーテルエーテルケトン樹脂（ＰＥＥＫ）、アクリロニトリル／ブタジエン／スチレン樹脂（ＡＢＳ樹脂）、ポリエチレン樹脂（ＰＥ樹脂）、ポリブチレンテレフタレート樹脂（ＰＢＴ樹脂）、ナイロン６６等（ＰＡ６６）のポリアミド樹脂（ＰＡ樹脂）、エポキシ樹脂、液晶ポリマー（ＬＣＰ樹脂）、変性ポリフェニレンエーテル樹脂（変性ＰＰＥ）、リアクター型軟質ポリプロピレン系樹脂（メタロセン系リアクター型ＴＰＯ樹脂）、ペルフルオロアルコキシフッ素樹脂（ＰＦＡ）、エチレン・四フッ化エチレン共重合体（ＥＴＦＥ）などである。また、合成樹脂部材２０は、上記のような熱可塑性樹脂に炭素繊維が配合された炭素繊維強化熱可塑性樹脂（ＣＦＲＴＰ）や、上記のような熱可塑性樹脂にガラス繊維、タルクなどの補強材や難燃化材や劣化防止剤やエラストマー成分などが配合されたものでもよい。
　（３）金属部材３０
　金属部材３０は、金属をブロック状、板状、又は線状等の所定形状に成形した部材である。金属部材３０を構成する金属としては、特に限定されず種々の金属を用いることができる。例えば、金属部材３０を構成する金属として銅（Ｃｕ）、鉄（Ｆｅ）、アルミニウム（Ａｌ）、チタン（Ｔｉ）、ニッケル（Ｎｉ）、クロム（Ｃｒ）等を用いることができる。また、金属部材３０は、銅合金、鉄合金（鉄鋼材）、アルミニウム合金、ステンレス、チタン合金、ニッケル合金、クロム合金等の２種以上の金属からなる合金から構成されてもよい。
　なお、金属部材３０は、常温（２５℃）において合成樹脂部材２０より硬度が高いことが好ましい。また、金属部材３０と合成樹脂部材２０とを接合する際に、金属部材３０の硬度が合成樹脂部材２０より高いことが好ましい。なお、金属部材３０と合成樹脂部材２０とを接合する際に、金属部材３０の硬度が合成樹脂部材２０より高く、接合した後常温下において金属部材３０より合成樹脂部材２０の硬度が高くなってもよい。ここで常温下における硬度とは、ＪＩＳ　Ｚ　２２４４に準拠して測定されるビッカース硬度であり、金属部材３０と合成樹脂部材２０とを接合する際に金属部材３０と合成樹脂部材２０が高温下にある場合、硬度とは、ＪＩＳ　Ｚ　２２５２に準拠して測定される高温ビッカース硬度である。
　金属部材３０の形状は、用途等に応じて所望の形状とすることができる。金属部材３０の成形方法は、任意の方法を適用することができ、所望の形状の型に溶融した金属等を流し込む鋳造や、工作機械等による切削加工や、プレス機械等による打ち抜き加工等を用いてもよい。
　また、金属部材３０は、金属接合面３２や後述するアンカ部３４に酸化膜（金属酸化物）が形成されていてもよい。酸化膜は、金属の表面に自然に形成された自然酸化膜であってもよい。また、酸化膜は、酸化剤による表面処理、陽極酸化による電解処理、プラズマ酸化処理、酸素含有気体中での加熱酸化処理等により金属部材３０の表面に形成されたものであってもよい。
　好ましい態様として、酸化膜は、空気中などの酸素含有気体の雰囲気下において、金属部材３０の表面を急速に加熱して金属部材３０の表面に形成されたものであってもよい。急速に加熱する際の１分間あたりの金属部材３０の表面の上昇温度は、金属部材３０を構成する金属の融点温度以上であることが好ましい。このように金属部材３０の表面を急速に加熱することで、金属部材３０の表面に緻密な酸化膜を形成することができる。しかも、金属部材３０の表面を急速に加熱することで、酸化膜の表面にマイクロクラックが発生し、合成樹脂部材２０との接合面積が大きくなる。
　なお、レーザ加熱、誘導加熱又は抵抗加熱など種々の方法によって金属部材３０の表面を急速に加熱することができるが、加熱時の昇温速度が速く、温度制御が容易であることから、レーザ光の照射によって金属部材３０の表面を加熱して酸化膜を形成することが好ましい。
　また、金属部材３０の金属接合面３２には、粗面化処理が施され、アンカ部３４が設けられている。
　（４）アンカ部３４
　金属接合面３２に形成されたアンカ部３４は、図２～図３に示すように、金属接合面３２から突出する突起３５を複数備える。複数の突起３５は、所定方向（以下、この方向を第１方向という）Ｘに沿って並んで設けられている。
　なお、本実施形態では、図２に示すように、金属接合面３２に５つのアンカ部３４が第１方向Ｘに垂直な方向（以下、この方向を第２方向）Ｙに間隔をあけて設けられているが、金属接合面３２に１つのアンカ部３４を設けてもよく、金属接合面３２に複数のアンカ部３４を第２方向２に間隔をあけて設けてもよい。また、金属接合面３２に複数のアンカ部３４を設ける場合、図２に示すように一のアンカ部３４が、他のアンカ部３４と平行に設けられてもよく、他のアンカ部３４に対して傾斜するように設けられてもよい。
　アンカ部３４を構成する各突起３５は、第１接合面３２から突出する凸条部３５ａと、凸条部３５ａの上部に設けられた膨張部３５ｂとを備える。
　凸条部３５ａは第１方向Ｘに延びる細幅の凸条状をなしている。好ましい態様として、凸条部３５ａは、第１方向Ｘに隣接する突起３５の凸条部３５ａと繋がっていてもよい。凸条部３５ａは、図２及び図３に示すようにアンカ部３４を構成する全ての突起３５を連結するように一続きに繋がっていてもよく、また、一部の凸条部３５ａが第１方向Ｘに隣接する突起３５の凸条部３５ａと連結されず、凸条部３５ａが第１方向Ｘの途中で分断されていてもよい。
　凸条部３５ａの上部に設けられた膨張部３５ｂは、凸条部３５ａより第２方向Ｙの両方へ広がった形状をなしている。これにより、各突起３５は膨張部３５ｂの下方に設けられた凸条部３５ａにおいて第２方向Ｙに細くくびれ、突起３５の第２方向Ｙの両側にアンダーカット部３５ｃが設けられている。なお、膨張部３５ｂは、略球体や、略楕円体や、複数の略球体を連結した立体など種々の形状とすることができる。
　このようなアンカ部３４を構成する各突起３５は、図３に示すような突起３５の頂部３５ｄを含む第１方向Ｘに沿った断面（以下、「第１方向断面」ということもある）の形状が、金属接合面３２側（つまり、金属接合面３２との接触部分）の第１方向Ｘに沿った長さが最も長くなるように、金属接合面３２に近づくほど第１方向Ｘに広がる形状をなしている。
　つまり、アンカ部３４を構成する各突起３５は、第１方向Ｘから見ると付け根部分（金属接合面３２側の部分）が細くくびれ（図４参照）、第２方向Ｙから見ると付け根部分が第１方向Ｘに広がっている（図３参照）。
　アンカ部３４を構成する複数の突起３５の各種寸法の一例を挙げると、金属接合面３２から突起３５の頂部３５ｄまでの長さ（突起３５の突出高さ）を５０μｍ～２００μｍ、凸条部３５ａの第２方向Ｙの長さを１０μｍ～１００μｍ、膨張部３５ｂの第２方向Ｙの長さを５０μｍ～２００μｍ、凸条部３５ａの第１方向Ｘの長さを５０μｍ以上、第１方向Ｘに隣接する突起３５の間隔を１μｍ～５００μｍとすることができる。なお、凸条部３５ａの第１方向Ｘの長さはアンカ部３４の第１方向Ｘの長さと等しくてもよい。
　好ましい態様として、アンカ部３４を構成する各突起３５は、図３に示すような第１方向断面における金属接合面３２との接触部分の長さＬｘが、図４に示すような頂部３５ｄを含む第２方向Ｙに沿った断面（以下、「第２方向断面」ということもある）における金属接合面３２との接触部分の長さＬｙより長くなっている。
　なお、アンカ部３４を構成する各突起３５の第１方向断面は、突起３５－１のように頂部３５ｄから金属接合面３２に近づくほど第１方向Ｘの長さが漸次長くなる形状であってもよく、また、突起３５－２のように第１方向Ｘに細くくびれた部分を有し、このくびれた部分の金属接合面３２側が第１方向Ｘに最も長くなるように第１方向Ｘへ広がった形状であってもよい（図３参照）。
　（５）接合体１０の製造方法
　次に、接合体１０の製造方法について説明する。
　まず、所定形状に成形した合成樹脂部材２０と金属部材３０を準備する。そして、金属部材３０の金属接合面３２にアンカ部３４を形成するアンカ形成工程を実行する。その後、アンカ部３４を形成した金属接合面３２に合成樹脂部材２０の樹脂接合面２２を接合する接合工程を行う。これにより、金属部材３０の金属接合面３２に合成樹脂部材２０が接合された接合体１０が得られる。以下、アンカ形成工程及び接合工程について詳述する。
　（５－１）アンカ形成工程
　アンカ形成工程では、金属部材３０のうち合成樹脂部材２０が接合される金属接合面３２に、下記式（１）で表される係数Ｒが０．１以上１．０以下を満たすパルス状のレーザ光を第１方向Ｘへ移動（走査）させながら照射することが好ましい。
Figure JPOXMLDOC01-appb-M000001
  
　式（１）中、ｈはレーザ光の周波数）、ｋは金属部材３０を構成する金属材料の熱拡散係数（ｍ２／ｓｅｃ）、ｔはレーザ光のパルス幅（ｓｅｃ）、ｖはレーザ光を走査させる走査速度（ｍ／ｓｅｃ）を表す。
　上記の係数Ｒが０．１以上１．０以下のパルス状のレーザ光を金属接合面３２に照射すると、第１方向Ｘから見ると付け根部分が細くくびれ、第２方向Ｙから見ると付け根部分が第１方向Ｘに広がっている突起３５が、第１の方向Ｘに沿って並んで設けられる。
　なお、酸素含有気体中において上記のようにレーザ光を照射してアンカ部３４を形成すると、アンカ部３４の表面に金属酸化物が形成される。
　また、複数のアンカ部３４を第２方向Ｙに間隔をあけて形成する場合、第２方向Ｙに所定間隔をあけた位置においてパルス状のレーザ光を第１方向Ｘへ走査させながら金属接合面３２に照射する。
　なお、金属部材３０の金属接合面３２にパルス状のレーザ光を照射してアンカ部３４を形成する前に、金属接合面３２においてアンカ部３４を形成する箇所にレーザ光を照射し、金属接合面３２に付着する不純物を除去する前処理を行ってもよい。
　（５－２）接合工程
　接合工程では、金属部材３０及び合成樹脂部材２０を加熱することで、合成樹脂部材２０の樹脂接合面２２側を軟化させる軟化工程を実行する。その後、樹脂接合面２２を複数の突起３５に接触させながら合成樹脂部材２０を金属部材３０へ加圧することで、複数の突起３５を合成樹脂部材２０に入り込ませて金属接合面３２を樹脂接合面２２に加圧しながら接触させる加圧工程を実行する。これにより、金属接合面３２に樹脂接合面２２が接合された接合体１０が得られる。本実施形態では、図５及び図６に示すような接合装置５０を用いて軟化工程及び加圧工程を行い、接合体１０を製造する。
　接合装置５０は、金属部材３０が載置されるステージ５１と、ステージ５１に載置された金属部材３０を誘導加熱する加熱装置５２と、合成樹脂部材２０を金属部材３０に加圧接合するプレス装置５３とを備える。
　ステージ５１には、アンカ部３４を設けた金属接合面３２が合成樹脂部材２０と対向するように金属部材３０が載置される。
　加熱装置５２は、電源装置（不図示）に接続された誘導加熱コイルを備え、電源装置から駆動電源が入力されると誘導加熱コイルから磁界を発生させてステージ５１に載置された金属部材３０の金属接合面３２を誘導加熱する。
　プレス装置５３は、セラミックス等の絶縁体で形成されたロッド５４と、ロッド５４を移動させて合成樹脂部材２０を金属部材３０の金属接合面３２に押し当てる加圧部５５とを備える。ロッド５４は、図５に示すように、加熱装置５２が有する誘導加熱コイルの中空部分に挿入され、合成樹脂部材２０と対向するように配置されていてもよい。加圧部５５は、電空レギュレータにより制御された空圧式シリンダや、スプリング式加圧器などを備え、ロッド５４とともに合成樹脂部材２０を移動させる速度と、合成樹脂部材２０を金属部材３０に押し当てる時の圧力を制御できることが好ましい。
　接合装置５０を用いて接合体１０を製造するには、まず、気体が存在する雰囲気において、アンカ部３４を設けた金属接合面３２がこの後にセッティングする合成樹脂部材２０と対向するように、ステージ５１の上に金属部材３０を載置する。
　次いで、樹脂接合面２２がステージ５１に載置した金属部材３０の金属接合面３２と間隔をあけて対向するように合成樹脂部材２０を配置する。金属部材３０の金属接合面３２と合成樹脂部材２０の樹脂接合面２２との間隔は、例えば、０．００１ｍｍ～１０ｍｍに設定される。
　次いで、合成樹脂部材２０を挟んで金属部材３０の金属接合面３２に対向するように加熱装置５２を配置する。図５に示す場合では、加熱装置５２を合成樹脂部材２０の上方に配置し、加熱装置５２と金属部材３０との間に合成樹脂部材２０を配置する。
　次いで、合成樹脂部材２０の樹脂接合面２２を第１の温度Ｔ１に加熱した気体に曝す軟化工程を実行する。
　具体的には、加熱装置５２に駆動電源を供給して、加熱装置５２に設けられた誘導加熱コイルから磁界を発生させて金属部材３０の金属接合面３２を加熱する。その際、金属部材３０の金属接合面３２が第１の温度Ｔ１になるように、加熱装置５２に供給する駆動電源や加熱装置５２に設けられた誘導加熱コイルの位置等を調整する。
　上記のような金属部材３０の加熱に伴って、金属部材３０と合成樹脂部材２０との間にある気体が第１の温度Ｔ１に加熱される。これにより、金属部材３０の金属接合面３２に対向する合成樹脂部材２０の樹脂接合面２２が、第１の温度Ｔ１に加熱された気体に曝され、樹脂接合面２２が第１の温度Ｔ１になる。そして、加熱装置５２は、金属部材３０の金属接合面３２を所定時間Ｓ１（例えば、１～１０秒間）加熱して合成樹脂部材２０の樹脂接合面２２側が軟化する軟化工程を実行し、その後、軟化工程を終了して加圧工程へ移行する。
　軟化工程が終了すると、引き続き加圧工程を実行するため、加熱装置５２は、金属部材３０の加熱を停止又は加熱量を低減して、樹脂接合面２２、金属接合面３２及びその周囲（金属部材３０と合成樹脂部材２０との間の気体）の温度が第２の温度Ｔ２になるまで降温（冷却）する。そして、第２の温度Ｔ２で合成樹脂部材２０と金属部材３０とを接合する。
　つまり、加圧工程では、第１の温度Ｔ１より低い温度（第２の温度Ｔ２）において、プレス装置５３が、合成樹脂部材２０を所定の速度Ｖで移動させて金属部材３０に衝突させる。このとき、合成樹脂部材２０は、ロッド５４の先端に対応した位置が金属部材３０に強く押し付けられ、所定の圧力Ｐで金属部材３０に押し付けられる。これにより、金属接合面３２に設けた複数の突起３５が合成樹脂部材２０の樹脂接合面２２側に入り込み、樹脂接合面２２が金属接合面３２に加圧状態で接触してすること接合体１０が得られる。そして、第２工程を終了する。
　ここで、第１の温度Ｔ１とは、合成樹脂部材２０を構成する熱可塑性樹脂の１．８ＭＰａの荷重を加えたときの荷重たわみ温度Ｔｆ以上の温度とすることができる。なお、合成樹脂部材２０が、熱可塑性樹脂に炭素繊維やガラス繊維やタルク等の補強材が配合された樹脂からなる場合、合成樹脂部材２０を構成する熱可塑性樹脂の１．８ＭＰａの荷重を加えたときの荷重たわみ温度Ｔｆとは、補強材を含まない熱可塑性樹脂の１．８ＭＰａの荷重を加えたときの荷重たわみ温度Ｔｆである。
　第１の温度Ｔ１の上限値は、合成樹脂部材２０を構成する熱可塑性樹脂の分解温度以下、つまり、熱可塑性樹脂が気化し始める温度より低い温度とすることができる。一例を挙げると、第１の温度Ｔ１の上限値を１０００℃としてもよい。好ましくは、合成樹脂部材２０を構成する熱可塑性樹脂の融点Ｔｍより２０℃高い温度に第１の温度Ｔ１の上限値を設定することができる。
　また、第２の温度Ｔ２は、第１の温度Ｔ１より低い温度であればよいが、合成樹脂部材２０を構成する熱可塑性樹脂の１．８ＭＰａの荷重を加えたときの荷重たわみ温度Ｔｆ以上であることが好ましい。第２の温度Ｔ２は、合成樹脂部材２０を構成する熱可塑性樹脂の融点Ｔｍより低い温度であることが好ましい。第１の温度Ｔ１と第２の温度Ｔ２との温度差は１℃以上２０℃以下であることが好ましい。
　なお、本明細書において、熱可塑性樹脂の融点Ｔｍは、ＪＩＳ　Ｋ７１２１に準じて、示差走査熱量測定器を用いて、昇温速度毎分１０℃で測定した値である。代表的な熱可塑性樹脂の融点を挙げると、ポリプロピレン樹脂は１６８℃、ナイロン６６は２６５℃、ポリブチレンテレフタレート樹脂は２３２～２６７℃、ポリフェニレンサルファイド樹脂は２８０℃である。
　また、熱可塑性樹脂の荷重たわみ温度Ｔｆは、ＪＩＳ　Ｋ７１９１に準じた方法で測定した１．８ＭＰａの荷重を加えたときの荷重たわみ温度である。代表的な熱可塑性樹脂の１．８ＭＰａの荷重を加えたときの荷重たわみ温度Ｔｆを挙げると、ポリプロピレン樹脂は５７～６５℃、ナイロン６６は６６～６８℃、ポリブチレンテレフタレート樹脂は５８℃、ポリフェニレンサルファイド樹脂は１０５℃である。
　なお、軟化工程は、空気などの酸素含有気体中で実行されることが好ましい。つまり、酸素含有気体の雰囲気において金属接合面３２及び樹脂接合面２２を第１の温度Ｔ１に加熱し、金属接合面３２及び樹脂接合面２２を第１の温度Ｔ１に加熱された酸素含有気体に曝すことが好ましい。
　酸素含有気体の雰囲気で軟化工程を実行すれば、合成樹脂部材２０の樹脂接合面２２が、酸素含有気体に含まれている酸素と反応することで、塩基性または両性の酸化物と中和反応して化学的に結合しうる官能基が合成樹脂部材２０の樹脂接合面２２に生成される。
　通常、金属部材３０の表面は、酸化され金属酸化物からなる酸化膜に被覆されているため、樹脂接合面２２に生成された官能基が金属部材３０の金属接合面３２に存在する金属酸化物とファンデルワールス力や水素結合によって接合する。加えて、合成樹脂部材２０と金属部材３０とを加熱及び加圧状態で接合することで、樹脂接合面２２の官能基が金属部材３０の金属酸化物と中和反応（脱水縮合）による共有結合を形成する。
　樹脂接合面２２に生成される官能基の一例を挙げると、合成樹脂部材２０を構成する熱可塑性樹脂の酸化分解により生成されたカルボキシル基（－ＣＯＯＨ）、カルボニル基（－ＣＯ－）、ヒドロキシ基（－ＯＨ）の少なくともいずれか１つを有している。合成樹脂部材２０を構成する熱可塑性樹脂がポリフェニレンサルファイド樹脂（ＰＰＳ）のようなイオウ原子（ヘテロ原子）を含む樹脂では、樹脂接合面２２が有する官能基としてはカルボキシル基、カルボニル基、ヒドロキシ基に加えて、スルホン基（－ＳＯ３Ｈ）、スルホニル基（－ＳＯ２－ ）、スルファニル基（－ＳＨ）、ジスルフィド基（－ＳＳ－ ）等のようなヘテロ原子を含む官能基を含んでもよい。
　金属部材３０と合成樹脂部材２０の接合により生じる中和反応の一例を挙げると、樹脂接合面２２が官能基としてカルボキシル基（Ｒ－ＣＯＯＨ）を有しており、金属部材３０が２価の金属から構成されている場合、下記式（２）のような中和反応が生じる。
２（Ｒ－ＣＯＯＨ）＋ＭｅＯ＝２（Ｒ－ＣＯＯ）－Ｍｅ＋Ｈ２Ｏ↑・・・（２）
　なお、式（２）中、Ｒは合成樹脂部材２０を構成する熱可塑性樹脂の主鎖、Ｍｅは金属部材３０を構成する金属である。
　また、酸素含有気体の雰囲気で軟化工程を実行する場合、第２の温度Ｔ２は、合成樹脂部材２０の樹脂接合面２２が有する官能基と、金属部材３０の金属接合面３２に形成された金属酸化物とが中和反応による共有結合を形成しうる温度であることが好ましい。また、第２の温度Ｔ２は、中和反応により発生した水が反応系から除去される温度であることが好ましい。第２の温度Ｔ２は、官能基及び金属酸化物の種類により変わるため、一概に規定することが困難であるが、中和反応により発生した水が除去されやすいことから１００℃以上であることがより好ましい。
　また、軟化工程において、金属部材３０及び合成樹脂部材２０の全体が第１の温度Ｔ１になるように金属部材３０及び合成樹脂部材２０を加熱してもよいが、樹脂接合面２２を第１の温度Ｔ１に加熱された気体に曝し、少なくとも金属接合面３２及び樹脂接合面２２が第１の温度Ｔ１になるように金属部材３０及び合成樹脂部材２０を加熱してもよい。これにより合成樹脂部材２０の樹脂接合面２２側が軟化して、加圧工程において突起３５が合成樹脂部材２０へ入り込みやすくなるとともに合成樹脂部材２０が変形するのを抑えることができる。合成樹脂部材２０の樹脂接合面２２側が金属部材３０より硬度が低くなるように軟化工程を行うことが好ましい。
　また、加圧工程において、合成樹脂部材２０を金属部材３０に押し当てる時の圧力Ｐは、合成樹脂部材２０を構成する熱可塑性樹脂の圧縮降伏応力以上の圧力であることが好ましい。この圧力Ｐは、合成樹脂部材２０を構成する熱可塑性樹脂により変わるため、一概に規定することが困難であるが、１０～１００ＭＰａであることが好ましい。
　また、本実施形態では、プレス装置５３が金属部材３０へ向けて合成樹脂部材２０を移動する場合について説明したが、金属部材３０を合成樹脂部材２０へ向けて移動させてもよい。
　また、本実施形態のように金属部材３０と合成樹脂部材２０を局所的に接合する場合、接合箇所の平面形状は点状、線状、面状など任意の形状であってもよい。
　また、加圧工程において、金属接合面３２に設けたアンカ部３４全体が加圧されるように合成樹脂部材２０を金属部材３０へ押し付けてもよく、また、アンカ部３４の一部が加圧されるように合成樹脂部材２０を局所的（スポット的）に金属部材３０へ押し付けてもよい。
　また、本実施形態において、合成樹脂部材２０を金属部材３０に押し付けている間、合成樹脂部材２０、金属部材３０及びその周囲の温度を第２の温度Ｔ２に保持してもよい。あるいはまた、合成樹脂部材２０、金属部材３０及びその周囲の温度が所定温度以下に冷却されるまで、合成樹脂部材２０を金属部材３０に加圧状態で接触させ続けても良い。その場合、合成樹脂部材２０、金属部材３０及びその周囲の温度が、合成樹脂部材２０を構成する熱可塑性樹脂のガラス転移温度Ｔｇ以下に冷却されるまで、合成樹脂部材２０を金属部材３０に加圧状態で接触させることが好ましい。
　また、本実施形態では、接合工程として、予め所定形状に成形した合成樹脂部材２０を加熱しながら金属部材３０に圧着する場合について説明したが、アンカ部３４が形成された金属部材３０を射出成形型内にインサートし、溶融した合成樹脂材料を射出成形型内で金属接合面３２へ向けて射出することで、金属部材３０に合成樹脂部材２０を接合してもよい。
　（６）効果
　本実施形態の接合体１０では、アンカ部３４を構成する複数の突起３５の第２方向Ｙの両側にアンダーカット部３５ｃが設けられているため、合成樹脂部材２０と金属部材３０との接合強度を高めることができる。
　また、複数の突起３５は、第１方向断面の形状が、金属接合面３２側において第１方向Ｘに沿った長さが最も長くなるように、金属接合面３２に近づくほど第１方向Ｘに広がる形状をなしている。そのため、アンカ効果を発揮しやすい形状を保持しつつ、金属接合面３２に対する複数の突起３５の接合強度を高めたり、合成樹脂部材２０の接合時や接合後に突起３５自体が破損しにくくなり、その結果、接合体１０の接合強度を向上することができる。
　しかも、アンカ部３４を構成する複数の突起３５が第１方向Ｘに沿って並んで設けられているため、金属接合面３２上に適度な間隔をあけつつ多数の突起３５を設けることができ、接合体１０の接合強度を向上することができる。
　本実施形態において第１方向Ｘに隣接する突起３５の凸条部３５ａが繋がっている場合、金属接合面３２に対する突起３５の接合強度を更に向上することができる。
　本実施形態において突起３５の第１方向断面が、突起３５のように頂部３５ｄから金属接合面３２に近づくほど第１方向Ｘの長さ漸次長くなる形状である場合、金属接合面３２に対する突起３５の接合強度を更に向上することができる。
　本実施形態において、金属部材３０の硬度が合成樹脂部材２０より高い場合、金属部材３０に設けた複数の突起３５を合成樹脂部材２０へ入り込ませやすくなるとともに、複数の突起３５が破損しにくくなり高いアンカ効果が得られる。
　本実施形態において、アンカ部３４の表面に金属酸化物が形成されている場合、合成樹脂部材２０の樹脂接合面２２が有する官能基が、アンカ部３４の金属酸化物と双極子相互作用によって接合する。加えて、樹脂接合面２２の官能基が金属酸化物と中和反応（脱水縮合）による共有結合を形成する。そのため、接合体１０の接合強度を向上することができる。
　（第２実施形態）
　次に本発明の第２実施形態について図７及び図８に参照して説明する。なお、第１実施形態と同一の構成のものについては同一の符号を付し、その構成の説明を省略する。
　本実施形態では、樹脂接合面２２に第１方向Ｘに沿って延びる溝２３が形成されている。この溝２３は、金属部材３０に設けられたアンカ部３４を構成する複数の突起３５に対応する位置に設けられている。接合工程において金属接合面３２に設けられた複数の突起３５が溝２３に嵌まり、接合体１００が得られる。
　なお、樹脂接合面２２に設けた溝２３に第３部材（以下、「充填部材」ということもある）２４を充填する充填工程を行うことが好ましい。充填部材２４を構成する材料としては、任意の材料を用いることができるが、金属部材３０と合成樹脂部材２０とを接合する際に金属部材３０より硬度が低い材料であることが好ましく、金属部材３０と合成樹脂部材２０とを接合した後に加熱硬化する材料を用いることがより好ましい。充填部材２４としてエポキシ樹脂やフェノール樹脂などの熱硬化性樹脂を用いることが好ましい。
　このような第２実施形態の接合体１００は、金属部材３０及び充填部材２４を加熱することで、充填部材２４を軟化させる軟化工程を実行する。その後、充填部材２４を複数の突起３５に接触させながら合成樹脂部材２０を金属部材３０へ加圧することで、複数の突起３５を充填部材２４に入り込ませて金属接合面３２を樹脂接合面２２に加圧しながら接触させる加圧工程を実行する。これにより、金属接合面３２に樹脂接合面２２が接合された接合体１００が得られる。
　本実施形態では、金属接合面３２に設けられた複数の突起３５が、樹脂接合面２２に設けられた溝２３に嵌まるため、合成樹脂部材２０に入り込みやすくなり接合工程を容易に行うことができる。
　また、樹脂接合面２２に設けた溝２３に充填部材２４が充填されている場合、複数の突起３５が溝２３から抜けにくくなり接合体１００の接合強度を向上することができる。
　（変更例）
　本発明は上記した実施形態に限定されない。上記の各実施形態は、例として提示したものであり、発明の範囲を限定することは意図していない。新規な実施形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことができる。
　例えば、上記した第１実施形態及び第２実施形態では、アンカ部３４を形成した金属部材３０と熱可塑性樹脂からなる合成樹脂部材２０とを接合する場合について説明したが、金属からなる金属部材同士を接合する場合や樹脂からなる樹脂部材同士を接合する場合にも本発明を適用することができる。
　また、上記した第１実施形態及び第２実施形態では、接合体１０の製造において、合成樹脂部材２０の樹脂接合面２２側を加熱によって軟化させる軟化工程を実行したが、加熱に加え、あるいは、加熱に変えて加湿などの方法によって軟化工程を行ってもよい。
　（実施例）
　以下、本発明の実施例及び比較例１，２を説明する。なお、本発明は、実施例に限定されるものではない。
　本実施例及び比較例１，２では、金属部材の金属接合面に第２方向Ｙへ０．５ｍｍ間隔毎に第１方向Ｘへ走査しながらレーザ光を照射することで、金属接合面のうち樹脂接合面と接触する箇所全体にアンカ部を形成した。そして、アンカ部を形成した金属接合面に合成樹脂部材を接合した。実施例及び比較例１，２において金属接合面に照射したレーザ光の条件は、下記表１に示した通りである。
　実施例及び比較例１，２に用いた金属部材及び合成樹脂部材の詳細、金属部材の寸法、合成樹脂部材の寸法、合成樹脂部材と金属部材との接合面積（オーバラップ面積）は、以下の通りである。
　・金属部材：表面にレーザ照射によって１秒間でＳＵＳ３０４の融点１４５０℃以上に加熱し酸化及び粗面化処理を施したＳＵＳ３０４
　・合成樹脂部材：サスティール（登録商標）ＳＧＸ１２０
　・金属部材の寸法：１８ｍｍ×４５ｍｍ×１．６ｍｍ
　・合成樹脂部材の寸法：１０ｍｍ×４０ｍｍ×３．０ｍｍ
　・金属部材と合成樹脂部材との接合面積：１０ｍｍ×５ｍｍ
　評価方法は次の通りである。
　（ａ）アンカ部のＳＥＭ観察
　金属接合面にアンカ部を形成した実施例及び比較例１，２の金属部材について、合成樹脂部材を接合していない状態でアンカ部のＳＥＭ観察を行った。図９～図１１は、実施例の金属部材の平面図及び断面図を示し、図９において符号Ｘは第１方向を示し、レーザ光を走査した方向、符号Ｙは第２方向を示す。
　図９に示すように、実施例の金属部材の金属接合面には、複数の突起が第１方向Ｘに沿って並んで設けられていた。金属接合面に設けられた複数の突起は、図１０に示すように、複数の突起の第１方向断面が突起の頂部から金属接合面に近づくほど第１方向Ｘの長さが長くなる形状をなしていた。また、図１１に示すように、複数の突起は、凸条部と、その上部に凸条部より第２方向Ｙの両方へ広がった膨張部を備え、突起の第２方向Ｙの両側にアンダーカット部が設けられていた。
　また、複数の突起は、頂部を含む前記第１方向に沿った断面形状が、金属接合面側において第１方向Ｘに最も長くなるように、金属接合面に近づくほど第１方向Ｘに広がる形状となり、第１方向断面における金属接合面との接触部分の長さが、第２方向断面における金属接合面３２との接触部分の長さより長くなっていた。
　比較例１の金属部材の金属接合面には、第１方向Ｘに延びる複数の凸条部が第２方向Ｙに間隔をあけて設けられていたが、凸条部の上部に膨張部が形成されていなかった。
　比較例２の金属部材の金属接合面には、第１方向Ｘに延びる複数の凹溝が第２方向Ｙに間隔をあけて設けられていたが、凸条部や膨張部は形成されていなかった。
　（ｂ）接合強度
　ＪＩＳ　Ｋ　６８５０に規定された試験方法のうち、金属部材の寸法、合成樹脂部材の寸法、合成樹脂部材と金属部材との接合面積を上記の通りに変更し、その他の条件を同規格に準じて、引張試験機（島津製作所、オートグラフ AGX-V）を用い、引張速度１０ｍｍ／ｍｉｎ、測定温度２５℃で測定した。なお、実施例及び比較例１，２の試験片をそれぞれ４個ずつ作製し、４個の測定値の平均値をそれぞれの接合強度とした。
Figure JPOXMLDOC01-appb-T000002
  
　結果は、比較例１、２では、２３．７ＭＰａ及び１７．７ＭＰａに対して実施例では２９．５ＭＰａであり、実施例の接合体では、大幅に接合強度を向上させることが確認できた。
１０…接合体、２０…合成樹脂部材、２２…樹脂接合面、３０…金属部材、３２…金属接合面、３４…アンカ部、３５…突起、３５ａ…凸条部、３５ｂ…膨張部、３５ｃ…アンダーカット部、３５ｄ…頂部

Claims (12)

  1. 　アンカ部が設けられた第１接合面を有する第１部材と、第２接合面を有する第２部材とを備え、前記第１接合面に前記第２接合面を接合した接合体において、
    　前記アンカ部は、前記第１接合面から突出し、第１方向に沿って並んで設けられた複数の突起を備え、
    　前記複数の突起は、
    　前記第１方向に垂直な方向である第２方向の両側にアンダーカット部を有し、
    　頂部を含む前記第１方向に沿った断面形状が、前記第１接合面側において前記第１方向に沿った長さが最も長くなるように、前記第１接合面に近づくほど前記第１方向に広がる形状をなしている接合体。
  2. 　前記複数の突起は、前記第１接合面から突出し前記第１方向に沿って延びる凸条部と、前記凸条部の上部に設けられ前記凸条部より前記第２方向へ広がった膨張部とを備える請求項１に記載の接合体。
  3. 　前記第１方向に隣接する前記複数の突起の前記凸条部が繋がっている請求項２に記載の接合体。
  4. 　前記複数の突起の頂部を含む前記第１方向に沿った断面が、頂部から前記第１接合面に近づくほど前記第１方向の長さが長くなる形状をなしている請求項１～３のいずれか１項に記載の接合体。
  5. 　前記第２部材は前記第２接合面に前記第１方向に沿って延びる溝を備え、前記溝に前記複数の突起が嵌まっている請求項１～４のいずれか１項に記載の接合体。
  6. 　前記溝に充填された第３部材を備える請求項５に記載の接合体。
  7. 　前記第１部材が、前記第２部材より硬度が高い請求項１～４のいずれか１項に記載の接合体。
  8. 　前記アンカ部の表面に金属酸化物が設けられている請求項１～７のいずれか１項に記載の接合体。
  9. 　アンカ部が設けられた第１部材の第１接合面に第２部材の第２接合面を接合した接合体の製造方法において、
    　前記第１接合面から突出し、複数の突起を有する前記アンカ部を形成するアンカ形成工程と、
    　前記アンカ形成工程後、前記第２部材を前記複数の突起に接触させながら加圧して、前記複数の突起を前記第２部材に入り込ませて前記第１接合面を前記第２接合面に接触させる接合工程とを備え、
    　前記アンカ形成工程は、前記第１接合面に対してパルスレーザ光を第１方向へ走査しながら照射することで、前記第１方向に垂直な方向である第２方向の両側にアンダーカット部を有し、頂部を含む前記第１方向に沿った断面形状が、前記第１接合面側において前記第１方向に沿った長さが最も長くなるように、前記第１接合面に近づくほど前記第１方向に広がる形状をなしている複数の突起を、前記第１方向に沿って並べて設ける接合体の製造方法。
  10. 　前記接合工程が、前記第２部材の前記第２接合面側を軟化させる軟化工程を備える請求項９に記載の接合体の製造方法。
  11. 　前記第２接合面に前記第１方向に沿って延びる溝を形成する溝形成工程を備え、
    　前記接合工程において前記溝に前記複数の突起を嵌める請求項９に記載の接合体の製造方法。
  12. 　前記溝形成工程が、前記溝に第３部材を充填する工程を備え、前記接合工程が、前記第３部材を軟化させる軟化工程を備える請求項１１に記載の接合体の製造方法。
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