An aluminum alloy material is prepared that has surface configuration of threefold irregularities such that rough surface having surface roughness of 10 to 100 μm period is observed with an electron microscope in a magnification of 1000 times, surface having fine irregularities of 1 to 5 μm period based on crystal grain boundary is observed with an electron microscope in a magnification of 10000 times and surface having ultrafine irregularities of 30 to 100 nm period is confirmed with an electron microscope in a magnification of 100000 times. Aluminum alloy material is integrally joined with a resin composition consisting of a total resin part containing polyphenylene sulfide resin by 70 mass % or more of the resin part, modified polyolefin resin by 30 mass % or less of the resin part and a resin of third component having ability for promoting compatibility of polyphenylene sulfide resin and modified polyolefin resin.
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 15/085 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising polyolefins
B32B 27/20 - Layered products essentially comprising synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
B29K 23/00 - Use of polyalkenes as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
An adhesive (B) of solvent containing adhesive as a suspension of low viscosity is prepared by adding a solvent MIBK to a one-part epoxy adhesive of a dicyandiamide-curable type (A). Metal shaped articles (M1 to M5) as adherends are prepared each of which, through various surface treatment, has specific surface configuration of roughened face and/or ultrafine irregularities and the surface is entirely covered with a thin layer of ceramics such as a metal oxide or metal phosphate. The specified face of each metal shaped article (M1 to M5) is painted with the solvent containing adhesive (B). The faces painted with the adhesive of two metal shaped articles (M1 to M5) are caused to abut each other, the articles are heated to cure the one-epoxy adhesive to accomplish adhesion. With one of the adherends replaced by a CFRP shaped article (P2), a composite of a metal and CFRP can be formed.
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
C09J 5/06 - Adhesive processes in generalAdhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
C09J 163/00 - Adhesives based on epoxy resinsAdhesives based on derivatives of epoxy resins
B29C 65/00 - Joining of preformed partsApparatus therefor
3.
Method for preparing a composite of metal and resin
It is an object of the present invention to securely and integrally join a metal and a resin, more particularly, a shaped titanium alloy substrate and a resin composition. A titanium alloy substrate is used that has undergone surface roughening by chemical etching or the like so as to have a ultrafine textured face in which bent, ridge-like protrusions having a width and height of from ten to a few hundred nanometers and a length of from a few to a few hundred microns rise up on the surface at a spacing period of from ten to a few hundred nanometers. A titanium alloy piece 1 with its surface treated is inserted into the cavity of a metallic mold for injection molding 10 and a specific resin composition 4 is injected to obtain an integrated composite 7. The main resin component of the resin composition 4 that is used can be a polyphenylene sulfide resin (PPS) or a polybutylene terephthalate resin (PBT). High injection joining strength is obtained if the resin composition contains, as an auxiliary component, a polyethylene terephthalate resin and/or polyolefin resin in the case of PBT and a polyolefin resin in the case of PPS.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 70/68 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers
C23F 1/26 - Acidic compositions for etching refractory metals
B29K 67/00 - Use of polyesters as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
B29K 705/00 - Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
There is provided a technique to strongly integrate a galvanized steel sheet and a resin molded article. A hot-dip galvanized steel sheet is immersed in an aqueous solution for aluminum degreasing to form a specific roughness on the surface. The surface is covered with convex protrusions having a diameter of about 100 nm, and a chromate treatment layer appears in the surface. A resin composition comprising 70 to 97 wt % of polyphenylene sulfide and 3 to 30 wt % of a polyolefin resin is injected onto the surface. The resin composition penetrates into ultra-fine irregularities and is cured in that state, and thereby a composite in which the galvanized steel sheet and the resin molded article are strongly integrated can be obtained. The shear rupture strength of the composite is extremely high.
C23C 22/00 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/00 - Joining of preformed partsApparatus therefor
B05D 7/00 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
C23C 22/06 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6
C23C 22/07 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6 containing phosphates
C23C 22/30 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6 containing hexavalent chromium compounds containing also trivalent chromium
C23C 22/33 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6 containing hexavalent chromium compounds containing also phosphates
C23C 22/36 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6 containing fluorides or complex fluorides containing also phosphates
C23C 22/50 - Treatment of iron or alloys based thereon
C23C 22/53 - Treatment of zinc or alloys based thereon
C23C 22/56 - Treatment of aluminium or alloys based thereon
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 15/18 - Layered products essentially comprising metal comprising iron or steel
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
C23F 1/00 - Etching metallic material by chemical means
B29C 65/44 - Joining a heated non-plastics element to a plastics element
B32B 5/14 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 27/20 - Layered products essentially comprising synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B32B 3/26 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids
It is an object to manufacture a composite of a metal part and a resin composition part, which is improved so as to securely join and integrate stainless steel and a resin. A stainless steel part whose surface has been suitably roughened by chemical etching or the like can be used. An integrated product is obtained by inserting a stainless steel piece 1 with its surface treated into a cavity formed by a movable-side mold plate 2 and a fixed-side mold plate 3 of a metallic mold for injection molding 10 and injecting a specific resin. PBT, PPS or an aromatic polyamide resin can be used as the main resin component of a resin composition 4 that is used. High injection joining strength is obtained if the resin composition contains, as an auxiliary component, PET and/or a polyolefin resin in the case of PBT, a polyolefin resin in the case of PPS and an aliphatic polyamide resin in the case of an aromatic polyamide resin.
C03C 15/00 - Surface treatment of glass, not in the form of fibres or filaments, by etching
D06N 7/00 - Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
C23C 22/05 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
C23F 1/22 - Acidic compositions for etching magnesium or alloys thereof
B32B 5/14 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
B32B 15/18 - Layered products essentially comprising metal comprising iron or steel
B32B 27/18 - Layered products essentially comprising synthetic resin characterised by the use of special additives
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
A method for preparing a copper alloy given a certain special surface shape yields tremendous bonding strength through compatibility with an epoxy resin adhesive. With a composite part in which this technology is utilized to integrate a copper alloy member as a cover material with a CFRP, it is possible to take advantage of the characteristics of both the copper alloy and the FRP due to the tremendous bonding strength. In a step in which an FRP prepreg is put into a mold and heated and cured, usually the mold is first coated with a release agent to facilitate release from the mold, but with high-technology CFRP, bleeding of the release agent often diminishes the properties. A copper alloy sheet 21 is used as a cover material, and a CFRP 22 is cured.
C03C 15/00 - Surface treatment of glass, not in the form of fibres or filaments, by etching
B32B 37/02 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
C23F 1/18 - Acidic compositions for etching copper or alloys thereof
B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 15/14 - Layered products essentially comprising metal next to a fibrous or filamentary layer
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
According to the present invention, the manufacturing process is simplified, the weight and cost are reduced, and a safe and reliable structure is obtained, using a generic metal plate. This heat exchanger has outer surfaces (4a, 5a) positioned on the side toward the electronic component (3) that is the object of heat exchange, and resin-coated inner surfaces (4b, 5b). A thin metal plate having a predetermined thickness is press-worked to a predetermined shape and a first shaped body (4) and a second shaped body (5) are formed. The two shaped bodies are combined so that the inner surface (4b, 5b)-sides face each other, and the inner surface (4b) at the edge parts (4c) and the inner surface (5b) at the edge parts (5c) are thermally fused by heat press-working. The edge parts (4c, 5c) are subjected to ultra-fine processing and then inserted into a die, and a thermoplastic resin composition is injected into the cavity of the die and a joining member (6) is shaped. The space section (7) created by the combining has a feed port (10) and an outlet port (11), and represents a fluid channel for a heat medium (8). The heat exchanger (1) is imparted with the structure described above. The outer surfaces (4a, 5a) are brought into contact with the electronic component (3) and heat exchange is performed with the heat medium flowing through the fluid channel.
A magnesium alloy part is inserted into a mold, a resin composition is injected and joined to the part, and a composite is obtained. A part having, formed thereon, a surface layer of a metal oxide, a metal carbonate, or a metal phosphate in use of a usual conversion treatment or a modification method thereof can be used for the magnesium alloy plate 1. The surface that has a larger amount of crystal-like objects of a nanolevel on the surface layer composed of the metal oxide, metal carbonate, or metal phosphate has a higher level of hardness, microscopic roughness, and good injection joining force, and these parameters can be controlled by a conversion treatment method. A resin composition 4, containing PBT or PPS as the main component, is used as the resin composition part.
C23C 22/07 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH < 6 containing phosphates
C23C 22/78 - Pretreatment of the material to be coated
B32B 27/06 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
C23C 22/05 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
C23F 1/22 - Acidic compositions for etching magnesium or alloys thereof
C23C 22/00 - Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
B29K 705/00 - Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
a and an aluminum alloy lid 61. These three members are inserted into an injection mold, and a thermoplastic resin composition 64 of PPS resin is injected. The lithium-ion battery lid 60 having a structure as shown in FIG. 11 is thus obtained.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
H01M 2/06 - Arrangements for introducing electric connectors into or through cases
According to the present invention, an IC tag can be securely fixed in a sealed state so as to endure boiling, sterilizing, etc., and information retained by the IC tag can be transmitted without fail. Provided is a medical apparatus to which an IC tag is fixed, wherein the IC tag, into which information necessary for management is written, is used in a medical information management system that reads and manages the information. The IC tag (2) is attached to the inside of a cover (3) which is divided in half and, at the same time, is attached to a medical apparatus main body (1). An adhesive member is injected into a cavity which is a space in the cover (3) from the cover (3) side. The IC tag (2) is enclosed inside the cover (3) and is fixed to the medical apparatus main body (1) in a sealed state.
The object of the present invention is to strongly join an aluminum alloy part with an FRP prepreg. An object obtained by subjecting an aluminum alloy to a suitable liquid treatment so as to form a surface having large, micron-order irregularities and also fine irregularities with a period of several tens of nanometers, eliminating the presence of sodium ions from the surface and additionally forming a surface film of aluminum oxide, which is thicker than a natural oxide layer, has been found to have a powerful adhesive strength with epoxy-based adhesives. By simultaneously curing an FRP prepreg which uses the same epoxy-based adhesive in the matrix, an integral composite or structure in which FRP and aluminum alloy have been united at a joining strength of unprecedented magnitude is produced.
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
A blank material is subjected to die press moulding such that a recessed and projected pattern is formed thereon, and subsequently trimmed to obtain a plate member. The plate member is bent to a semi-cylindrical shape, steeped in an aqueous solution of a water-soluble amine compound, and a surface thereof is covered with ultrafine recesses having a diameter in the range of 20-80nm. Having undergone surface treatment, two semi-cylindrical-shaped plate members are placed together to form a cylindrical shape which is subsequently inserted into an injection moulding die. A polyphenylene sulphide (PPS) resin is injected onto the surface of both plate members, injection molding is conducted, and both plate members are bound together by the moulded resin article. As a result, a heat dissipating member for LED bulbs can be manufactured using a low-cost and simple method.
F21V 29/00 - Protecting lighting devices from thermal damageCooling or heating arrangements specially adapted for lighting devices or systems
B29C 33/12 - Moulds or coresDetails thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
In the composite, an aluminum-plated steel sheet and a resin are securely and integrally joined together. Through chemical etching, the aluminum-plated steel sheet is caused to have a surface configuration, in which three-dimensional protrusions having shapes with a minor diameter of at least 0.3 μm and a major diameter of at least 3 μm are scattered over a plain part and a portion covered with shallow fine recesses with a diameter of 20 to 50 nm in a state of being distributed adjacent to each other on the plain part accounts for 30 to 50% of the surface area of the plain part. The surface of the three-dimensional protrusions is mainly ceramic containing silicon and the plain part is mainly ceramic containing aluminum. The resin is joined through injection molding with the aluminum-plated steel sheet having been inserted into a metallic mold.
The present invention provides a metal resin complex having high gas sealing performance. An aluminum alloy structure having a shape that winds the periphery of a copper electrode (63) is produced at first, the winding aluminum alloy is closely adhered to the copper electrode (63), and the aluminum alloy is subjected to a pressing or forging process to allow the aluminum alloy to dig into the copper electrode (63). The copper electrode (63) is then processed mechanically into a predetermined shape, thereby producing the copper electrode (63) having the aluminum alloy member (61a) attached thereto. Subsequently, three members, i.e., an aluminum electrode (62), the copper electrode (63) having the aluminum alloy member (61a) attached thereto, and an aluminum alloy lid (61), are subjected to an NMT or NMT2 surface treatment, the three members are inserted into an injection molding mold, and a thermoplastic resin composition (64) which comprises a PPS resin is ejected, whereby a lithium ion battery lid (60) is produced.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
C23F 1/36 - Alkaline compositions for etching aluminium or alloys thereof
An object of the present invention is to obtain a composite in which a copper or copper alloy is securely integrated with and joined to PBT or PPS. A copper product that has been suitably roughened by chemical etching and also blackened can be used favorably. A surface-treated copper piece 1 is inserted into a cavity formed by a movable molding plate 2 and a stationary molding plate 3 of an injection molding mold 10, and a specific resin is injected to obtain an integrated product. PBT or PPS can be used as the resin component of a resin composition 4 that is used here. High injection joining strength is obtained if the resin composition contains, as an auxiliary component, PET and/or a polyolefin resin in the case of PBT, and a polyolefin resin in the case of PPS.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 15/09 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising polyesters
16.
Composite of steel and resin and method for manufacturing same
In the composite, an aluminum-plated steel sheet and a resin are securely and integrally joined together. Through chemical etching, the aluminum-plated steel sheet is caused to have a surface configuration, in which three-dimensional protrusions having shapes with a minor diameter of at least 0.3 μm and a major diameter of at least 3 μm are scattered over a plain part and a portion covered with shallow fine recesses with a diameter of 20 to 50 nm in a state of being distributed adjacent to each other on the plain part accounts for 30 to 50% of the surface area of the plain part. The surface of the three-dimensional protrusions is mainly ceramic containing silicon and the plain part is mainly ceramic containing aluminum. The resin is joined through injection molding with the aluminum-plated steel sheet having been inserted into a metallic mold.
B32B 5/16 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer formed of particles, e.g. chips, chopped fibres, powder
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
A process which comprises applying a one-part epoxy adhesive, a phenol resin adhesive, or an unsaturated polyester resin based adhesive to a metal alloy piece; inserting the resulting metal alloy piece with the adhesive into an injection mold; injecting the same thermosetting resin composition as the resin of the adhesive into the mold; and thus forming a composite wherein a shaped article of the metal alloy and the thermosetting resin composition are unified with a layer of the adhesive therebetween, wherein the metal alloy piece has previously been subjected to NAT treatment in a manner so that: (1) an uneven surface where the roughness period is 1 to 10 μm and the height difference is up to about a half of the roughness period is formed, (2) ultrafine irregularities with a period of 10 to 500 nm, most desirably 50 to 100 nm are formed on the inside-wall surfaces of the concaves, and (3) the surface is covered with a thin layer of a hard ceramic phase. In the process, the thermosetting resin is injection -bonded to the metal alloy, whereby the obtained composite exhibits excellent corrosion resistance, weather resistance, and heat resistance owing to the combination of a molded product of the thermoplastic resin and the shaped article of the alloy.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
B29C 65/70 - Joining of preformed partsApparatus therefor by moulding
An object of the present invention is to create, from a titanium alloy and an FRP prepreg, a composite of a titanium alloy and an FRP material that is suitable for bolt fastening. The composite can bring out excellent characteristics in CFRP members in mobile electronic-electric devices, mobile equipment, medical instruments, marine devices and the like. It has been found that titanium alloy having a special constant surface shape adheres strongly with an epoxy adhesive. In a composite obtained using this technique to integrate a titanium alloy member as a cover material and a CFRP material, the metal alloy portion deforms and disperses locally strong forces so that the CFRP material is not damaged, even when the composite is assembled to another metal member through bolt-fastening. As a result, the composite is expected to be effective for applications in mobile equipment or mobile device casings, where lightweightness, corrosion resistance, toughness and ease of assembly are required.
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 15/14 - Layered products essentially comprising metal next to a fibrous or filamentary layer
C09J 163/00 - Adhesives based on epoxy resinsAdhesives based on derivatives of epoxy resins
B32B 5/14 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 15/06 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of rubber
B32B 27/20 - Layered products essentially comprising synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
The object of the present invention is to strongly join an aluminum alloy part with an FRP prepreg. An object obtained by subjecting an aluminum alloy to a suitable liquid treatment so as to form a surface having large, micron-order irregularities and also fine irregularities with a period of several tens of nanometers, eliminating the presence of sodium ions from the surface and additionally forming a surface film of aluminum oxide, which is thicker than a natural oxide layer, has been found to have a powerful adhesive strength with epoxy-based adhesives. By simultaneously curing an FRP prepreg which uses the same epoxy-based adhesive in the matrix, an integral composite or structure in which FRP and aluminum alloy have been united at a joining strength of unprecedented magnitude is produced.
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
B32B 43/00 - Operations specially adapted for layered products and not otherwise provided for, e.g. repairingApparatus therefor
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
C09J 163/00 - Adhesives based on epoxy resinsAdhesives based on derivatives of epoxy resins
Provided are: a composite obtained by tenaciously bonding a metal alloy to a molded article of an aliphatic polyamide resin; and a process for producing the composite. (1) A surface of a metal alloy is caused to have a micrometer-order roughness in which the contour curve elements have an average length (RSm) of 0.8-10 µm and a maximum height (Rz) of 0.2-5 µm. (2) In the surface having the roughness, microfine irregularities having a period of 5-500 nm are formed. (3) A surface layer is converted to a thin layer of a metal oxide or metal phosphate. This metal alloy is inserted into an injection mold. A polyamide resin composition composed of a resin ingredient comprising 56 mass% PA66 and 44 mass% PA610 and glass fibers with which the resin ingredient is filled is injected so as to be disposed on the surface of the alloy. The polyamide resin composition injected comes into the microfine irregularities and then solidifies. Thus, the metal alloy is tenaciously bonded to the resultant molded article of the polyamide resin composition.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
A composite of a magnesium part or a magnesium alloy part and a resin composition, improved to have high corrosion resistance, is manufactured by: a step of shaping a magnesium alloy part 1 from a casting or an intermediate material; a step of immersing and chemically etching the shaped part in an acidic aqueous solution; a step of immersing the chemically etched shaped part in an aqueous solution containing potassium permanganate and forming on the surface thereof a thin layer having manganese oxide as a component; a step of inserting the part, on which the thin layer has been formed, into a metallic mold for injection molding and injecting into the mold a resin composition selected out of a resin composition whose main component is polyphenylene sulfide, a resin composition whose main component is a polybutylene terephthalate resin and a resin composition whose main component is an aromatic polyamide resin and then integrally affixing the magnesium alloy part 1 and the resin composition 4; and a step of subjecting the integrally affixed composite 7 to a chemical conversion treatment by immersing it again in a magnesium alloy chemical conversion treatment solution.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
22.
Composite of metal and resin and method for manufacturing same
A composite of a metal part and a resin composition part that is improved so that the metal and resin are integrally joined to have strong bonding properties, and a method for manufacturing the composite. A magnesium alloy part is inserted into a mold, a resin composition is injected and joined to the part, and a composite is obtained. A part having, formed thereon, a surface layer of a metal oxide, a metal carbonate, or a metal phosphate in use of a usual conversion treatment or a modification method thereof can be used for the magnesium alloy plate 1. The surface that has a larger amount of crystal-like objects of a nanolevel on the surface layer composed of the metal oxide, metal carbonate, or metal phosphate has a higher level of hardness, microscopic roughness, and good injection joining force, and these parameters can be controlled by a conversion treatment method. A resin composition 4, containing PBT or PPS as the main component, is used as the resin composition part.
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
23.
Composite of aluminum alloy and resin and manufacturing method thereof
The surface of an aluminum alloy shaped product is covered with ultrafine recesses by being dipped in an eroding aqueous solution, or has formed thereon a metal oxide layer covered with the openings of ultrafine pores by anodizing. On the resin side, there is prepared a polyamide resin compounded with an impact resistance modifier, a mixture of an aliphatic polyamide and an aromatic polyamide, or a mixture of aromatic polyamides. The aluminum alloy shaped product is inserted into an injection mold, and a polyamide-type resin composition is injected onto the surface of the aluminum alloy shaped product, to manufacture an integrated composite.
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
B29C 44/04 - Shaping by internal pressure generated in the material, e.g. swelling or foaming for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
24.
BONDED BODY OF GALVANIZED STEEL SHEET AND ADHEREND, AND MANUFACTURING METHOD THEREFOR
Disclosed is a technique for securily integrating a galvanized steel sheet and a molded resin article. A galvanized steel sheet 'Z18' is immersed in an aqueous aluminum-degreasing solution heated to a temperature of 75℃ for seven minutes to form a surface with roughness such that the RSm is 0.8−2.3&mgr;m and the Rz is 0.3−1.0&mgr;m. The galvanized steel sheet surface is also covered with convex protrusions with diameters of approximately 100nm, and a chromate-treated layer, thus fulfilling three conditions ideal for bonding. The surface is sprayed with a resin composition including 70−97 mass% of a polyphenylene sulfide and 3−30 mass% of a polyolefin resin. The resin composition infiltrates the ultrafine concavities and hardens to create a securily integrated composite body of a galvanized steel sheet and a molded resin article. The composite body has an extremely high shear/rupture strength of over 20MPa.
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
25.
BONDED OBJECT OF METAL/ALLOY AND ADHEREND AND PROCESS FOR PRODUCING THE SAME
Provided is a technique for tenaciously bonding a metal or an alloy to an adherend, e.g., a GFRP, with an adhesive containing an unsaturated polyester resin as a major component. A surface of the metal or alloy is subjected to etching for (1) making the surface have a micrometer-order roughness having an average distance between crests or troughs (RSm) of 0.8-10 쎽m and a maximum height or roughness (Rz) of 0.2-5 쎽m, (2) forming ultrafine irregularities having a period of 5-500 nm in the surface having that roughness, and (3) converting a surface layer to a thin layer of a metal oxide or phosphorylated metal. On the other hand, an inorganic filler and an ultrafine inorganic filler are dispersed in an unsaturated polyester resin using a sand grinding mill. Thereafter, an organic peroxide is added to complete an unsaturated polyester adhesive. This unsaturated polyester adhesive is applied to the metal or alloy surface, and the adherend is fixed to the area where the adhesive has been applied. The uncured resin is cured by heating to unite the two members with each other.
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 15/09 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising polyesters
C23F 1/00 - Etching metallic material by chemical means
26.
COMPOSITE OF STEEL PRODUCT AND RESIN AND PROCESS FOR PRODUCING THE COMPOSITE
Disclosed is a composite comprising an aluminum-plated steel plate material and a resin strongly bonded integrally with the aluminum-plated steel plate material. Also disclosed is a steel plate material having corrosion resistance. Three-dimensional protrusions having a stone-like shape with a surface diameter of not less than about 0.3 &mgr;m or having an irregular shape with a short axis of not less than 0.3 &mgr;m and a major axis of several micrometers or more formed by chemical etching of the aluminum-plated steel plate material are scattered on a plain part. On the plain part, in such a state that shallow concaves having a diameter of 20 to 50 nm are distributed adjacent to each other, 30 to 50% of the area of the plain part is accounted for by the shallow concaves. The surface of the three-dimensional protrusions is mainly formed of a ceramic containing silicon. The plain part is mainly formed of a ceramic containing aluminum. A steel product is heated, and a resin molded product is pressure bonded and fused to the steel product followed by injection bonding or by bonding to other adherend with a resin-type adhesive. Further, coating may be performed for corrosion resistance imparting purposes.
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
C23C 28/00 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and
C23F 1/00 - Etching metallic material by chemical means
A metal alloy can be tenaciously bonded to an adherend with an epoxy adhesive by subjecting the alloy to a surface treatment based on NAT (nano-adhesion technology). This technology enables a composite of a metal alloy and a CFRP to be produced with an epoxy adhesive. In order to further improve the strength of adhesion between the metal alloy and the CFRP, carbon nanotubes were added to the epoxy adhesive. As a result, the carbon nanotubes penetrated micrometer-order recesses and protrusions formed in the metal alloy surface and improved the adhesion strength. Thus, a member constituted of a metal alloy and a CFRP tenaciously bonded thereto can be obtained. This member is extremely lightweight despite the high adhesion. By using the metal alloy to constitute an end part of the member, the member and another part can be easily assembled with a bolt and nut, etc., and easily disassembled.
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
A composite obtained by tenaciously uniting and bonding a shape made of a brass alloy to a thermoplastic resin. Also provided is a composite obtained by tenaciously uniting a shape made of a brass alloy with a shape of the same metal, a shape of another metal, or a molded resin by bonding with an adhesive. Furthermore provided are improved processes for producing the composites. A surface of a shape made of a brass alloy is regulated so as to result in such a roughness that the average contour curve element length is 0.5-10 쎽m and the maximum contour curve height is 0.1-5.0 쎽m. This shape is subjected to a chemical reaction treatment so that the surface is occupied with minute projections having a diameter of 30-150 nm. Thus, a brass alloy shape having a surface coated with a thin layer consisting mainly of cupric oxide is obtained. A thermoplastic resin composition is bonded and united to the brass alloy shape by injection bonding or press fusion bonding to form a composite. Shapes which are made of a brass alloy and have undergone the surface treatment are united with each other by bonding with an adhesive, or a shape which is made of a brass alloy and has undergone the surface treatment is united with a shape of another metal or a molded resin by bonding with an adhesive. Thus, a composite is obtained.
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
A composite of a metal and a resin, in which a shaped metal and a shaped thermoplastic resin are integrally joined by injection molding, and in which the perpendicular precision of the thermoplastic shaped body with respect to the shaped metal is improved, as well as a method for manufacturing the composite. A composite 40 of a metal and a resin is composed of a shaped metal 20 and a shaped thermoplastic resin that is integrally joined to this shaped metal 20 by injection molding. The shaped thermoplastic resin comprises a seat 42 and a boss 41 that protrudes from the seat 42. A runner 43 is provided which communicates with the seat 42 via two sprues and through which a molten thermoplastic resin that has been injected through an injection gate 45 flows into the boss 41 and the thermoplastic resin injected through the injection gate 45 flows through the sprues 47 to opposite locations of the boss 41 substantially uniformly, thereby filling the locations. As a result, the boss 41 can be joined perpendicularly to the shaped metal 20 by injection joining.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/70 - Joining of preformed partsApparatus therefor by moulding
B32B 3/10 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sinteringApparatus specially adapted therefor
B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniquesApparatus therefor
B29C 45/00 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor
This invention provides a process for producing a metal-resin composite, which can join a resin molded component, composed mainly of an engineering resin such as PBT or PPS, or a super engineering plastic resin, to a metal alloy component without any adhesive agent. A resin molded component is previously produced by injection molding using a resin composition composed mainly of a hard crystalline thermoplastic resin such as PBT, PPS, a polyamide resin, or a liquid crystal polymer. On the other hand, the surface of a metal alloy is chemically etched to provide a surface roughness on a micron order, wherein the mean spacing of profile irregularities (RSm) is 0.8 to 10 쎽m and the maximum roughness height (Rz) is 0.2 to 5 쎽m, and further to form on its surface ultrafine irregularities (concaves and convexes) having a cycle of 5 to 500 nm. In this case, the surface layer is a thin layer formed of a metal oxide or a metal phosphate. The metal alloy component is heated to a temperature above the melting point of the hard crystalline thermoplastic resin constituting the resin molded component, and the previously produced resin molded component is pressed against and fused to the surface of the heated metal alloy.
B29C 65/20 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated tool with direct contact, e.g. using "mirror"
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
31.
COMPOSITE OF METAL WITH RESIN AND PROCESS FOR PRODUCING THE SAME
A composite of a metal with a resin in which the metal and the resin, especially a shaped base made of an ordinary steel material and a resin composition, can be tenaciously bonded and united to each other; and a process for producing the composite. A surface of a shaped ordinary steel material is treated by chemical etching or the like to form a thin iron autoxidation film layer the surface of which almost wholly has ultrafine irregularities. Hydrazine, ammonia, or a water-soluble amine is chemically adsorbed onto the treated steel material. The resultant steel material shape (1) is inserted into an injection die (10), and a specific resin composition (4) is injected thereinto. The surface of the steel material shape (1) may have a thin layer of a metal oxide or metal-phosphorus oxide. By this injection, a composite (7) is obtained in which the ordinary steel material has been tenaciously bonded and united to the resin. The resin composition (4) to be used contains a crystalline polyphenylene sulfide resin (PPS) or polybutylene terephthalate resin (PBT) as the main resin component.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
C23F 1/28 - Acidic compositions for etching iron group metals
B29K 67/00 - Use of polyesters as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
A general steel product and an FRP prepreg are strongly bonded to each other to facilitate mechanical connection and disassembly of bolts, nuts and the like and thus to provide an excellent structural material, for example, for mobile equipment, structural members for building materials, and electronic and electrical equipment. It has been found that steel products, which are special products and have given and ultrafine concavoconvexes, can develop strong bonding force through compatibility with an epoxy resin adhesive. This technique can be utilized to prepare a composite component (26) comprising a steel plate (28) as a cover material integrated to FRP (27). The composite component (26) can be integrated with another metallic member by fastening with a bolt (30). Further, a member for a structure comprising FRP (27) as a main structure and a steel product as an end part can easily be produced by taking advantage of strong adhesive power.
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
C09J 163/00 - Adhesives based on epoxy resinsAdhesives based on derivatives of epoxy resins
C23F 1/28 - Acidic compositions for etching iron group metals
33.
TITANIUM ALLOY COMPOUND MATERIAL, AND ITS JOINTING METHOD
Provided is a compound material of a titanium alloy and an FRP material, which is made a titanium alloy and an FRP prepreg and which can suit a bolt fastening. The compound material can exhibit excellent characteristics for CFRP members for a mobile electronic-electric device, a mobile machine, a medical tool or a marine device. It is found that the titanium alloy having a special constant surface shape is adhered by a strong force to an epoxy adhesive. In the compound material which is integrated with the CFRP material by using the titanium alloy member as a cover material in accordance with that technique, the metal alloy portion deforms and disperses the locally strong force, even in case the compound material is assembled by fastening it to another metal member through a bolt, so that the CFRP material is not damaged. As a result, the compound material is expected to be effective for applications to mobile machines or mobile device casings, which are desired to be light, wear-resistant and strong and to be easily assembled.
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
C09J 163/00 - Adhesives based on epoxy resinsAdhesives based on derivatives of epoxy resins
C23F 1/26 - Acidic compositions for etching refractory metals
34.
MAGNESIUM ALLOY COMPOUND MATERIAL, AND ITS MANUFACTURING METHOD
Provided is a compound material of a light and strong magnesium alloy and a CFRP, which is made by adhering the magnesium alloy and the CFRP strongly by an epoxy adhesive. The magnesium alloy having a predetermined super-fine corrugating shape establishes an intense adhesion together with the epoxy resin adhesive. A magnesium alloy compound plate material (23), in which a magnesium alloy plate (25) and a CFRP (24) are integrated by utilizing the technique, can adopt the ordinary assembly structure of other metal members (28) and bolts (27). A locally strong force can be received by the magnesium alloy plate (25), so that the CFRP (24) is not damaged. As a result, the compound material is effective for applications to the casings, bodies or parts of moving machines or mobile devices such as automobiles, which are desired to be super-light and strong and to be easily assembled.
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
C09J 163/00 - Adhesives based on epoxy resinsAdhesives based on derivatives of epoxy resins
C23F 1/22 - Acidic compositions for etching magnesium or alloys thereof
35.
STAINLESS STEEL COMPLEX AND ITS MANUFACTURING METHOD
A CFRP-integrated stainless steel complex used for a hydrogen containing tank, a food processing machine, a medical device, a general-purpose machine, and other machines can be designed as a further rational design product with a smaller weight. It has been found that a stainless steel material (22) having particular ultra-micro convex/concave shapes exhibits an excellent adhesive force in combination with an epoxy resin adhesive agent. By using the technique, a stainless steel thick plate piece (22) is used as a cover material in combination with a CFRP (21) to obtain a stainless steel complex (20). This can be assembled with other metal member by tightening bolts. Moreover, by using the excellent adhesive force, it is possible to easily create a structure member having a main portion of CFRP (21) and an end portion of metal. This can be easily assembled with and disassembled from other part by using bolts/nuts and screws.
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
C09J 5/02 - Adhesive processes in generalAdhesive processes not provided for elsewhere, e.g. relating to primers involving pretreatment of the surfaces to be joined
A composite having the bonding strength between copper alloy and carbon fiber prepreg maximized is produced. It has been found that a copper alloy with special specified surface configuration creates an extraordinary bonding strength due to the compatibility with epoxy resin adhesive. By the use of technology based on this finding, a composite part consisting of a copper alloy member as a cover material integrated with a CFRP material realizes direct acquisition of both of the respective characteristics of copper alloy and FRP due to the presence of the extraordinary bonding strength. In the step of thermal hardening of FRP prepreg placed in a mold, although it is customary to coat the mold with a mold release agent in advance for the purpose of smoothing release from the mold, the CFRP making extensive use thereof often encounters a deterioration of properties because of penetration of the mold release agent. When CFRP (22) is hardened using a copper alloy plate (21) as a cover material, this problem is solved and important parts whose exterior elements consist of copper can be easily produced.
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
C09J 5/02 - Adhesive processes in generalAdhesive processes not provided for elsewhere, e.g. relating to primers involving pretreatment of the surfaces to be joined
A method by which an aluminum alloy part is tenaciously bonded to an FRP prepreg. An aluminum alloy is treated with an adequate liquid to form an aluminum oxide surface film having a surface which has large recesses and protrusions on the order of micrometer and has microfine recesses and protrusions having a period of tens of nanometers and in which no sodium ions are present. This aluminum oxide surface film is thickener than layers formed by natural oxidation. The aluminum alloy part thus treated brings about intensive bonding strength between the alloy and an epoxy adhesive. An epoxy adhesive applied to the aluminum alloy part is cured simultaneously with an FRP prepreg employing the same epoxy adhesive as a matrix. Thus, an FRP/aluminum alloy composite or structure is produced in which the constituent parts have been united at a high bonding strength that has not been attained so far.
B32B 15/092 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising epoxy resins
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
C23F 11/18 - Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent in other liquids using inorganic inhibitors
38.
METAL/RESIN COMPOSITE AND PROCESS FOR PRODUCING THE SAME
A composite of metal part and resin composition part improved so as to attain a strengthened integrative junction between stainless steel and a resin is produced. Use can be made of a stainless steel part provided with an appropriate roughened surface by chemical etching, etc. Integrated article can be obtained by inserting surface treated stainless steel piece (1) in a cavity defined by movable lateral mold platen (2) and fixed lateral mold platen (3) of injection molding metal mold (10) and injecting any of specified resins. PBT, PPS or an aromatic polyamide resin can be used as a main resin component of resin composition (4) for use. When the resin composition contains as a subcomponent PET and/or a polyolefin resin in the case of PBT, a polyolefin resin in the case of PPS and an aliphatic polyamide resin in the case of an aromatic polyamide resin, high injection junction strength can be generated.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
C23F 1/00 - Etching metallic material by chemical means
B29K 23/00 - Use of polyalkenes as moulding material
B29K 67/00 - Use of polyesters as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
Strengthened integrative junction between a metal and a resin, especially between a shaped titanium alloy substratum and a resin composition is attained. Use is made of a titanium alloy substratum with its surface roughened by chemical etching, etc. to a surface with ultrafine asperity such that curved projections like a mountain chain of 10 nm to hundreds of nanometers width and height and hundreds of microns to some microns length stand together in large numbers on a plane at an interval cycle of 10 nm to hundreds of nanometers. Integrated composite (7) can be obtained by inserting surface treated titanium alloy piece (1) in a cavity of injection molding metal mold (10) and injecting any of specified resin composition (4). Polyphenylene sulfide resin (PPS) or polybutylene terephthalate resin (PBT) can be used as a main resin component of resin composition (4) for use. When the resin composition contains as a subcomponent a polyethylene terephthalate resin and/or a polyolefin resin in the case of PBT and a polyolefin resin in the case of PPS, high injection junction strength can be generated.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
C23F 1/26 - Acidic compositions for etching refractory metals
B29K 23/00 - Use of polyalkenes as moulding material
B29K 67/00 - Use of polyesters as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
A process for the production of a highly corrosion-resistant composite which is composed of both a magnesium part or a magnesium alloy part and a resin composition and which is improved in corrosion resistance, comprising the step of forming a magnesium alloy part (1) out of an ingot or an intermediate material, the step of immersing the magnesium alloy part in an aqueous acid solution to conduct chemical etching, the step of immersing the chemically etched part in an aqueous solution of potassium permanganate to form a thin layer containing manganese oxide as the main component on the surface of the part, the step of inserting the resultingpart into an injection mold and injecting one member selected from among resin compositions comprising polyphenylene sulfide as the main component, resin compositions comprising polybutylene terephthalate resin as the main component, and resin compositions comprising aromatic polyamide resins as the main component into the resulting mold to unite the part (1) and the resin composition (4) and thus form a composite (7), and the step of immersing the composite (7) again in a chemical conversion treatment solution for magnesium alloys to conduct chemical conversion treatment.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
C23F 1/22 - Acidic compositions for etching magnesium or alloys thereof
B29K 23/00 - Use of polyalkenes as moulding material
B29K 67/00 - Use of polyesters as moulding material
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
A composite obtained by tenaciously uniting and bonding copper or a copper alloy to PBT or PPS. A copper part having a surface which has been adequately roughened by chemical etching and then blackened can be advantageously used. A surface-treated copper piece (1) is inserted into a cavity formed with the movable plate (2) and retainer plate (3) of a mold (10) for injection molding. A specific resin is injected thereinto to thereby obtain a united article. The resin in the resin composition (4) to be used may comprise PBT or PPS. When the resin composition comprises PBT or PPS, it may contain a PET and/or polyolefin resin or a polyolefinresin, respectively, as a minor component. This composition brings about a high injection bond strength.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 15/09 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising polyesters
B29K 67/00 - Use of polyesters as moulding material
B29K 81/00 - Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
42.
COMPOSITE OF METAL WITH RESIN AND PROCESS FOR PRODUCING THE SAME
A metal/resin composite obtained by uniting and bonding a metal shape and a thermoplastic resin shape by injection molding (injection bonding), wherein the accuracy of the perpendicularity of the thermoplastic resin shape to the metal shape has been improved. The metal/resin composite (40) comprises a metal shape (20) and a thermoplastic resin shape united with and bonded to one side of the metal shape (20) through injection molding. The thermoplastic resin shape comprises a pedestal (42) and a boss part (41) vertically disposed on this pedestal (42). The pedestal (42) has runners (43) which are connected to the pedestal (42) through two gates and through which a molten thermoplastic resin injected from an injection gate (45) is introduced into the boss part (41). Thus, the thermoplastic resin injected from the injection gate (45) approximately evenly flows into opposed parts of the boss part (41) through the gates (47) and fills the boss part (41). Due to this constitution, the boss part (41) can be bonded perpendicularly to the metal shape (20) by injection bonding.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/70 - Joining of preformed partsApparatus therefor by moulding
43.
ALUMINUM ALLOY-RESIN COMPOSITE AND METHOD OF PRODUCING THE SAME
⏧PROBLEMS] To establish both of the advantages of a metallic case and the advantages of a synthetic resin structure in electronic devices, electrical household appliances and so on while achieving a high productivity, enabling mass production and allowing free design of the shape and the structure. To provide a material which is highly useful in various lightweight and high-intensity parts and constructs without restricted to electronic devices or electrical household appliances. ⏧MEANS FOR SOLVING PROBLEMS] An aluminum alloy-based material is dipped in a corrosive aqueous solution to form microconcaves coating the surface. Alternatively, it is subjected to anodic oxidization to form a metal oxide layer coated with ultrafine openings. As the resin component, a polyamide resin compounded with a material having improved shock resistance, a mixture of an aliphatic polyamide with an aromatic polyamide, or a mixture of aromatic polyamides is prepared. The aluminum alloy-based material is inserted into an injection molding die and the polyamide-based resin composition is injected onto the surface thereof to give an integrated composite product.
B32B 15/088 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin comprising polyamides
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
patents
