The Complex Including A Resin Member Made Of A Resin Material Including A Polyefin And A Metal Member And Method For Manufacturing The Same
Abstract:
A composite body (106) of the present invention is obtained by joining a resin member (105) , which is formed of a resin material containing a polyolefin , to a metal member (103) with a primer layer (104) interposed therebetween. The resin member (105) is obtained by injection molding the resin material, and a coexistent layer , in which the resin material and a primer resin material that constitutes the primer layer (104) are coexistent , is formed between the primer layer (104) and the resin member (105). The coexistent layer has a thickness of from 5 nm to 50 nm (inclusive).
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Notices, Deadlines & Correspondence
SPECIFICATION
COMPLEX AND METHOD FOR MANUFACTURING COMPLEX
5 TECHNICAL FIELD
[0001]
The present invention relates to a complex to which a resin member
including a polyolefin and a metal member are joined, and a method
for manufacturing the complex.
10
BACKGROUND ART
[0002]
A technique to join a resin member and a metal member is required
in a wide range of fields such as the manufacturing of components
15 used in, for example, an automobile, a home appliance, an industrial
device, and the like.
[0003]
In recent years, as the technique to join a resin member and
a metal member, a method of joining a resin member and a metal member
20 by injection molding the resin member into the metal member, that
is, a so-called ^injection joining method' has been proposed.
[0004]
In the injection joining method, for example, a resin member
and a metal member are joined together by injecting into the metal
25 member having fine protrusions and recesses on the surface an
engineering plastic having a polar group with an affinity to the metal
member. Narutomi and colleagues along with Taisei plas Co., Ltd.
2
have been conducting active studies regarding the injection joining
method, and the technique is described in patent documents (for
example, Patent Documents 1 to 5 and the like).
[0005]
5 Narutomi and colleagues disclose a technique to join byinjection
a polybutylene terephthalate resin (hereinafter, referred
to as XPBT') or a polyphenylene sulfide resin (hereinafter, referred
to as APPS' ) to an aluminum alloy (for example, refer to Patent
Document 1) . In addition, a technique in which a large hole is
10 provided in an anode oxide film of an aluminum material, and a
synthetic resin body is fused into the hole, and is fixed using an
anchor effect is disclosed (for example, refer to Patent Document
2) .
[0006]
15 A non-polar polyolefin having no affinity to a metal member is
not easily attachable to a metal member. On the other hand, an
acid-modified body of a polyolefin into which a polar group has been
introduced can be attached to a metal member. However, for the
attachment, it is necessary to hold the polyolefin in a melted state,
20 and maintain the metal meraber and the polyolefin in contact with each
other at a high pressure for a long period of time. Therefore,
generally, a polyolefin and a metal member are joined together using
a lamination method through melt extrusion, a pressing method, or
the like.
25
RELATED DOCUMENT
PATENT DOCUMENT
3
[0007]
[Patent Document 1] Japanese Unexamined Patent Publication No.
2004-216425
[Patent Document 2] Pamphlet of International Publication No.
5 WO2004/055248
[Patent Document 3] Japanese Unexamined Patent Publication No.
2009-6721
[Patent Document 4] Japanese Unexamined Patent Publication No.
2010-64496
10 [Patent Document 5] Pamphlet of International Publication No.
WO2003/064150
DISCLOSURE OF THE INVENTION
[0008]
15 Compared with the above-described lamination method, pressing
method, and the like, the injection joining method has advantages
in the fast molding cycle, the high degree of freedom in shape, and
the like. However, there was a tendency that the resin was abruptly
cooled and was thus solidified within a short period of time, and
20 therefore a period of time during which the resin in a melted state
and the metal member were in contact with each other was short.
According to the studies by the present inventors, it was found
that, even when a metal member had fine protrusions and recesses molded
on the surface-treated surface, it was more difficult than expected
25 to join a polyolefin represented by a propylene-based polymer and
the metal member compared with the above-described PBT or PPS.
[0009]
4
The invention has been made in consideration of the
above-described technical background, and achieves the following
object. An object of the invention is to provide a complex having
excellent joining strength between a metal member represented by an
5 aluminum alloy component or a magnesium alloy component and a resin
member including a polyolefin having a light weight, high stiffness,
and excellent cost performance which is represented by polypropylene.
[0010]
The inventors conducted intensive studies regarding the
10 injection joining between a resin member including a polyolefin and
a metal member. As a result, the inventors found that, when a primer
layer is formed on at least a part of the surface of the metal member,
and a resin material including a polyolefin is molded by injection
onto the surface of the primer layer under specific conditions, a
15 complex having excellent joining strength between the resin member
and the meal member is obtained, and completed the invention.
[0011]
That is, according to the invention, there are provided a complex
and a method for manufacturing the complex described below.
20 [0012]
[1] A complex including a resin member made of a resin material
including a polyolefin and a metal member which are joined through
a primer layer,
in which the resin member is obtained by molding the resin
25 material by injection,
a coexistence layer in which a primer resin material configuring
the primer layer and the resin material coexist is formed between
5
the primer layer and the resin member, and
a thickness of the coexistence layer is in a range of more than
or equal to 5 nm and less than or equal to 50 rati.
[0013]
5 [2] The complex according to the above-described [1] ,
in which the resin member includes a shear orientation layer.
[0014]
[3] The complex according to the above-described [1] or [2],
in which the complex includes a resin intrusion layer in which
10 the metal member and the primer layer are present in a combined form.
[0015]
[4] The complex according to the above-described [3],
in which a thickness of the resin intrusion layer is in a range
of more than or equal to 5 nm and less than or equal to 100 nm.
15 [0016]
[5] The complex according to the above-described [3] or [4],
in which the metal member has fine protrusions and recesses
formed in at least a portion in contact with the primer layer, and
the resin intrusion layer is formed by infiltration of the primer
20 resin material into the protrusions and recesses.
[0017]
[6] The complex according to any one of the above-described [1]
to [5],
in which the resin member is obtained by molding the resin
25 material by injection into a mold in which the metal member has been
installed under conditions satisfying the following requirements (1)
to (4),
6
(1) when a temperature of the resin material during injection
molding is represented by Ti [°C], and a melting point of the polyolef in
is represented by T2 [°C], the Ti is in a range of T2+70
Documents
Orders
Section
Controller
Decision Date
Application Documents
#
Name
Date
1
9838-DELNP-2014-IntimationOfGrant22-12-2021.pdf
2021-12-22
1
9838-DELNP-2014.pdf
2014-11-22
2
9838-DELNP-2014-PatentCertificate22-12-2021.pdf
2021-12-22
2
Power of authority.pdf
2014-11-24
3
PCT-IB-304.pdf
2014-11-24
3
9838-DELNP-2014-Written submissions and relevant documents [09-12-2021(online)].pdf
2021-12-09
4
Other relevant document.pdf
2014-11-24
4
9838-DELNP-2014-Correspondence to notify the Controller [26-11-2021(online)].pdf