Composite structure and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-12291605-B2
Application number	US-202017788367-A
Country	US
Kind code	B2
Filing date	Dec 11, 2020
Priority date	Dec 27, 2019
Publication date	May 6, 2025
Grant date	May 6, 2025

Abstract

The invention is directed to a composite structure in which a metal member having a roughened surface and a resin member are joined in a state in which at least a portion of the roughened surface is included. The resin member is made of a molded article obtained by melt-molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin. In the roughened surface, a cumulative pore volume of a pore diameter in a range of 0.1 μm to 20 μm is in a range of 0.5 nL/mm 2 or more and 5 nL/mm 2 or less measured by mercury porosimetry. According to the invention, it is possible to provide a composite structure that is obtained by joining a metal member and a molded article made of polyarylene sulfide resin composition and is more excellent in joining strength, heat cycle resistance, and sealing properties, and a method for producing the composite structure.

First claim

The invention claimed is:

1. A composite structure in which a metal member having a roughened surface and a resin member are joined in a state in which at least a portion of the roughened surface is included, wherein
the resin member is made of a molded article obtained by melt-molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin (A),
in the roughened surface, a cumulative pore volume of a pore diameter in a range of 0.1 μm to 20 μm is in a range of 0.5 nL/mm 2 or more and 5 nL/mm 2 or less measured by mercury porosimetry,
the roughened surface has a pore diameter of 5 μm or less in which a pore distribution shows a maximum value in the pore diameter in the range of 0.1 μm to 20 μm measured by the mercury porosimetry, and
the polyarylene sulfide resin (A) has a melt viscosity in a range of 5 Pa's or more and 500 Pa's or less, wherein the melt is viscosity measured using a Koka flow tester after being held at 300° C., a load of 1.96×106 Pa, and L/D=10 (mm)/1 (mm) for 6 minutes.

2. The composite structure according to claim 1 , wherein
the roughened surface has a cumulative pore volume of less than 10 nL/mm 2 measured by a nitrogen gas adsorption method.

3. The composite structure according to claim 2 , wherein
the polyarylene sulfide resin composition has a melt viscosity at 300° C. in a range of 100 Pa·s or more and 7000 Pa·s or less at a shear rate of 12/s and in a range of 40 Pa·s or more to 800 Pa·s or less at a shear rate of 1200/s.

4. The composite structure according to claim 2 , wherein
the polyarylene sulfide resin composition is obtained by blending a filler (B) in a range of 1 part by mass to 150 parts by mass relative to 100 parts by mass of the polyarylene sulfide resin (A) and melt-kneading the mixture.

5. The composite structure according to claim 2 , wherein
the polyarylene sulfide resin composition is obtained by blending an elastomer (C) in a range of 0.01 parts by mass to 30 parts by mass relative to 100 parts by mass of the polyarylene sulfide resin (A) and melt-kneading the mixture.

6. The composite structure according to claim 2 , wherein
the polyarylene sulfide resin composition is obtained by blending a silane coupling agent (D) in a range of 0.01 parts by mass to 5 parts by mass relative to 100 parts by mass of the polyarylene sulfide resin (A) and melt-kneading the mixture.

7. The composite structure according to claim 1 , wherein
the polyarylene sulfide resin composition has a melt viscosity at 300° C. in a range of 100 Pa·s or more and 7000 Pa·s or less at a shear rate of 12/s and in a range of 40 Pa·s or more to 800 Pa·s or less at a shear rate of 1200/s.

8. The composite structure according to claim 1 , wherein
the polyarylene sulfide resin composition is obtained by blending a filler (B) in a range of 1 part by mass to 150 parts by mass relative to 100 parts by mass of the polyarylene sulfide resin (A) and melt-kneading the mixture.

9. The composite structure according to claim 1 , wherein
the polyarylene sulfide resin composition is obtained by blending an elastomer (C) in a range of 0.01 parts by mass to 30 parts by mass relative to 100 parts by mass of the polyarylene sulfide resin (A) and melt-kneading the mixture.

10. The composite structure according to claim 1 , wherein
the polyarylene sulfide resin composition is obtained by blending a silane coupling agent (D) in a range of 0.01 parts by mass to 5 parts by mass relative to 100 parts by mass of the polyarylene sulfide resin (A) and melt-kneading the mixture.

11. A method for producing a composite structure in which a metal member having a roughened surface and a resin member are joined in a state in which at least a portion of the roughened surface is included, the resin member being made of a molded article obtained by melt-molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin, the method comprising:
a step (α) of joining by melt-molding the polyarylene sulfide resin composition on a surface of the metal member, or a step (β) of joining the surface of the metal member and the molded article, wherein
in the roughened surface, a cumulative pore volume of a pore diameter in a range of 0.1 μm to 20 μm is in a range of 0.5 nL/mm 2 or more and 5 nL/mm 2 or less measured by mercury porosimetry,
the roughened surface has a pore diameter of 5 μm or less in which a pore distribution shows a maximum value in the pore diameter in the range of 0.1 μm to 20 μm measured by the mercury porosimetry, and
the polyarylene sulfide resin has a melt viscosity in a range of 5 Pa·s or more and 500 Pa's or less, wherein the melt is viscosity measured using a Koka flow tester after being held at 300° C., a load of 1.96×106 Pa, and L/D=10 (mm)/1 (mm) for 6 minutes.

12. The method for producing a composite structure according to claim 11 , wherein
the roughened surface has a cumulative pore volume of less than 10 nL/mm 2 measured by a nitrogen gas adsorption method.

Assignees

• Dainippon Ink & Chemicals

Inventors

• Nakamura Kenji
• Kanda Tomomichi

Classifications

• B32B2266/104

  Micropores, i.e. with average diameter in the range from 0.1 µm to 0.1 mm · CPC title

• B32B2266/045

  Metal · CPC title

• B32B3/26

  characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer} · CPC title

• C08K5/54

  Silicon-containing compounds {(C08K5/0091 takes precedence)} · CPC title

• C08G75/0281

  Recovery or purification · CPC title