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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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Patent Information

Application #
Filing Date
20 November 2014
Publication Number
32/2015
Publication Type
INA
Invention Field
GENERAL ENGINEERING
Status
Email
remfry-sagar@remfry.com
Parent Application
Patent Number
Legal Status
Grant Date
2021-12-22
Renewal Date

Applicants

MITSUI CHEMICALS INC.
5 -2, Higashi- Shimbashi 1- chome ,Minato- ku ,Tokyo 1057117

Inventors

1. OKUMURA Hiroshi
c/o Mitsui Chemicals Inc. 580 32 Nagaura Sodegaura- shi, Chiba 2990265
2. UCHIDA Kiminori
c/o Mitsui Chemicals ,Inc., 580- 32, Nagaura ,Sodegaura- shi, Chiba 2990265
3. KIMURA Kazuki
c/o Mitsui Chemicals, Inc., 580- 32, Nagaura ,Sodegaura- shi, Chiba 2990265
4. INOUE Goro
c/o Mitsui Chemicals, Inc. ,580- 32, Nagaura, Sodegaura- shi, Chiba 2990265
5. ISAKI Takeharu
c/o Mitsui Chemicals, Inc., 580- 32, Nagaura ,Sodegaura- shi, Chiba 2990265

Specification

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 2021-11-26
5 Form 5.pdf 2014-11-24
5 9838-DELNP-2014-FORM 3 [23-11-2021(online)].pdf 2021-11-23
6 Form 3.pdf 2014-11-24
6 9838-DELNP-2014-US(14)-HearingNotice-(HearingDate-02-12-2021).pdf 2021-11-09
7 Form 2+ Specificaiton.pdf 2014-11-24
7 9838-DELNP-2014-Correspondence-080819.pdf 2019-08-10
8 Drawings.pdf 2014-11-24
8 9838-DELNP-2014-Power of Attorney-080819.pdf 2019-08-10
9 9838-DELNP-2014-ABSTRACT [07-08-2019(online)].pdf 2019-08-07
9 9838-delnp-2014-Form-3-(08-01-2015).pdf 2015-01-08
10 9838-DELNP-2014-CLAIMS [07-08-2019(online)].pdf 2019-08-07
10 9838-delnp-2014-Form-1-(08-01-2015).pdf 2015-01-08
11 9838-DELNP-2014-COMPLETE SPECIFICATION [07-08-2019(online)].pdf 2019-08-07
11 9838-delnp-2014-Correspondence Others-(08-01-2015).pdf 2015-01-08
12 9838-DELNP-2014-DRAWING [07-08-2019(online)].pdf 2019-08-07
12 9838-DELNP-2014-FER.pdf 2019-02-26
13 9838-DELNP-2014-FER_SER_REPLY [07-08-2019(online)].pdf 2019-08-07
13 9838-DELNP-2014-Verified English translation (MANDATORY) [22-05-2019(online)].pdf 2019-05-22
14 9838-DELNP-2014-OTHERS [07-08-2019(online)].pdf 2019-08-07
14 9838-DELNP-2014-PETITION UNDER RULE 137 [07-08-2019(online)].pdf 2019-08-07
15 9838-DELNP-2014-OTHERS [07-08-2019(online)].pdf 2019-08-07
15 9838-DELNP-2014-PETITION UNDER RULE 137 [07-08-2019(online)].pdf 2019-08-07
16 9838-DELNP-2014-FER_SER_REPLY [07-08-2019(online)].pdf 2019-08-07
16 9838-DELNP-2014-Verified English translation (MANDATORY) [22-05-2019(online)].pdf 2019-05-22
17 9838-DELNP-2014-FER.pdf 2019-02-26
17 9838-DELNP-2014-DRAWING [07-08-2019(online)].pdf 2019-08-07
18 9838-DELNP-2014-COMPLETE SPECIFICATION [07-08-2019(online)].pdf 2019-08-07
18 9838-delnp-2014-Correspondence Others-(08-01-2015).pdf 2015-01-08
19 9838-DELNP-2014-CLAIMS [07-08-2019(online)].pdf 2019-08-07
19 9838-delnp-2014-Form-1-(08-01-2015).pdf 2015-01-08
20 9838-DELNP-2014-ABSTRACT [07-08-2019(online)].pdf 2019-08-07
20 9838-delnp-2014-Form-3-(08-01-2015).pdf 2015-01-08
21 9838-DELNP-2014-Power of Attorney-080819.pdf 2019-08-10
21 Drawings.pdf 2014-11-24
22 9838-DELNP-2014-Correspondence-080819.pdf 2019-08-10
22 Form 2+ Specificaiton.pdf 2014-11-24
23 9838-DELNP-2014-US(14)-HearingNotice-(HearingDate-02-12-2021).pdf 2021-11-09
23 Form 3.pdf 2014-11-24
24 9838-DELNP-2014-FORM 3 [23-11-2021(online)].pdf 2021-11-23
24 Form 5.pdf 2014-11-24
25 Other relevant document.pdf 2014-11-24
25 9838-DELNP-2014-Correspondence to notify the Controller [26-11-2021(online)].pdf 2021-11-26
26 PCT-IB-304.pdf 2014-11-24
26 9838-DELNP-2014-Written submissions and relevant documents [09-12-2021(online)].pdf 2021-12-09
27 Power of authority.pdf 2014-11-24
27 9838-DELNP-2014-PatentCertificate22-12-2021.pdf 2021-12-22
28 9838-DELNP-2014.pdf 2014-11-22
28 9838-DELNP-2014-IntimationOfGrant22-12-2021.pdf 2021-12-22

Search Strategy

1 9838DELNP2014searchstrategy(1)_25-04-2018.pdf

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