Metal-resin composite and method for producing same

Patent metadata

Field	Value
Publication number	US-11565480-B2
Application number	US-201917282847-A
Country	US
Kind code	B2
Filing date	Oct 10, 2019
Priority date	Oct 12, 2018
Publication date	Jan 31, 2023
Grant date	Jan 31, 2023

Abstract

There is provided a method for producing a metal-resin composite which includes a resin member and a metal member having a roughened surface in at least a portion of the surface thereof, the resin member being joined so as to be in contact with at least a portion of the roughened surface. The method includes a step of joining the resin member and the metal member by melting the resin member with the frictional heat generated in the surface of the metal member on its side opposite to the resin member in a state where the metal member and the resin member are superposed. The method includes making adjustment so that when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value.

First claim

The invention claimed is:

1. A method for producing a metal-resin composite containing a metal member, which has a roughened surface in at least a portion of the surface thereof, and a resin member, the resin member being joined so as to be in contact with at least a portion of the roughened surface, the method comprising:
a step of joining the resin member and the metal member by melting the resin member with the frictional heat generated in the surface of the metal member on its side opposite to the resin member in a state where the metal member and the resin member are superposed,
wherein when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value;
wherein when the roughened surface is measured at arbitrary four straight-line portions by using the stylus-type roughness meter according to ISO 4287, average length (RSm) of roughness curve elements is 36 to 60 μm.

2. The method for producing a metal-resin composite according to claim 1 , wherein the frictional heat is generated by pressing a rotating tool on the surface of the metal member on its side opposite to the resin member.

3. The method for producing a metal-resin composite according to claim 1 , wherein the melt viscosity of the resin member is 200 to 6000 Pa·s.

4. The method for producing a metal-resin composite according to claim 1 , wherein the resin member contains a polyarylene sulfide resin.

5. A metal-resin composite comprising a metal member and a resin member which are joined together,
wherein the resin member contains at least a thermoplastic resin;
the metal member has a roughened surface in at least a portion of the surface thereof, and when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value;
when the roughened surface is measured at arbitrary four straight-line portions by using the stylus-type roughness meter according to ISO 4287, average length (RSm) of roughness curve elements is 36 to 60 μm;
the resin member and the metal member are joined together by melting the resin member with the frictional heat generated in the surface of the metal member on its side opposite to the resin member in the state the resin member is superposed so as to be in contact with at least a portion of the roughened surface; and
the melting point of the thermoplastic resin is 260° C. or more.

6. The metal-resin composite according to claim 5 , wherein the resin member has a melt viscosity in the range of 200 Pas to 6000 Pa·s.

7. The metal-resin composite according to claim 5 , wherein the metal member is a member selected from the group consisting of an aluminum alloy, a magnesium alloy, a copper alloy, and a titanium alloy, aluminum die cast, aluminum and copper.

8. A metal-resin composite comprising a metal member and a resin member which are joined together,
wherein the resin member contains at least a thermoplastic resin;
the metal member has a roughened surface in at least a portion of the surface thereof, and when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value;
when the roughened surface is measured at arbitrary four straight-line portions by using the stylus-type roughness meter according to ISO 4287, average length (RSm) of roughness curve elements is 36 to 60 μm;
the resin member is joined so as to be in contact with at least a portion of the roughened surface;
the surface of the metal member has a press mark on its side opposite to the resin member; and
the melting point of the thermoplastic resin is 260° C. or more.

9. The metal-resin composite according to claim 8 , wherein the press mark present in the surface of the metal member has a concave shape in a sectional view and a shape having independent one or two or more circles in a front view.

10. The metal-resin composite according to claim 8 , wherein the press mark present on the surface of the metal member has a concave shape in a sectional view and a shape in a front view which independent one or two or more circular press marks overlap to form an overall straight-line shape, an overall shelf-like shape, an overall lattice-like or network shape, or an overall zigzag shape.

11. The metal-resin composite according to claim 8 , wherein the resin member has a melt viscosity in the range of 200 Pa·s to 6000 Pa·s.

12. The metal-resin composite according to claim 8 , wherein the metal member is a member selected from the group consisting of an aluminum alloy, a magnesium alloy, a copper alloy, and a titanium alloy, aluminum die cast, aluminum and copper.

Assignees

• Dainippon Ink & Chemicals

Inventors

• Nakamura Kenji
• Kanda Tomomichi
• Kikuchi Hideaki

Classifications

• B32B15/08

  of synthetic resin · CPC title

• B29C66/742 Primary

  to metals or their alloys · CPC title

• B29C65/0681 Primary

  created by a tool · CPC title

• B29C66/244

  said joint lines being non-straight, e.g. forming non-closed contours · CPC title

• B29C66/234

  said joint lines being in the form of tessellations · CPC title