Metal-and-resin composite and method for making same

Patent metadata

Field	Value
Publication number	US-2016107342-A1
Application number	US-201514595443-A
Country	US
Kind code	A1
Filing date	Jan 13, 2015
Priority date	Oct 20, 2014
Publication date	Apr 21, 2016
Grant date	—

Abstract

A metal-resin composite includes a metal member and a resin member, the metal member has a plurality of metal posts formed on a surface of the metal member, the resin member is filled spaces between adjacent metal posts and covers the surface of the metal member to bond with the metal member.

First claim

What is claimed is:

1 . A metal-resin composite comprising:
a metal member having a plurality of metal posts on a surface of the metal member; and a resin member being filled in spaces between adjacent metal posts and covering the surface of the metal member to bond with the metal member.

2 . The metal-resin composite as claimed in claim 1 , wherein each metal post has a diameter of about 0.01 mm to about 1 mm, and the length of each metal post is about 2 μm to about 15 μm along a direction extending from the metal member to the resin member.

3 . The metal-resin composite as claimed in claim 2 , wherein each end of the metal posts away from the metal member further has a metal lug connected with a corresponding metal post, the thickness of each metal lug is about 4 μm to about 8 μm, the resin member is filled the spaces between adjacent metal posts and covers the surface of the metal member and the metal lugs to bond with the metal member.

4 . The metal-resin composite as claimed in claim 1 , wherein each metal post has a diameter of about 0.01 mm to about 1 mm, the length of each metal post is about 2 μm to about 20 μm along a direction extending from the metal member to the resin member, and the surface roughness of each metal post is about 2.0 μm to about 5.0 μm.

5 . The metal-resin composite as claimed in claim 4 , wherein each end of the metal posts away from the metal member further has a metal lug connected with a corresponding metal post, the thickness of each metal lug is about 4 μm to about 8 μm, the surface roughness of the metal posts is about 2.0 μm to about 5.0 μm, the resin member is filled the spaces between adjacent metal posts and covers the surface of the metal member and the metal lugs to bond with the metal member.

6 . The metal-resin composite as claimed in claim 4 , wherein the metal posts and the metal lugs are both selected from a group consisting of Au, Ag, Cu, Ni, Zn, Sn, Al and Cr.

7 . The metal-resin composite as claimed in claim 4 , wherein the metal member is selected from a group consisting of stainless steel, aluminum, aluminum alloy, magnesium, magnesium alloy, copper, copper alloy, zinc and zinc alloy.

8 . The metal-resin composite as claimed in claim 4 , wherein the resin member is selected from a group consisting of polybutylene terephthalate, polyphenylene sulfide, polyethylene terephthalate, polyether ether ketone, polycarbonate, polyvinyl chloride polymer, polyurethane resin, epoxy, polyurea resin and acrylic resin.

9 . A metal-resin composite comprising:
a metal member, the metal member having a metal layer, the metal layer defining a plurality of micro-pores; and a resin member, the resin member being filled into the micro-pores and covering the metal layer to bond with the metal member.

10 . The metal-resin composite as claimed in claim 9 , wherein the metal layer is selected from a group consisting of Au, Ag, Cu, Ni, Zn, Sn, Al and Cr.

11 . The metal-resin composite as claimed in claim 9 , wherein the surfaced roughness of the metal layer is about 2.0 μm to about 5.0 μm, the thickness of the metal layer is about 2 μm to about 20 μm.

12 . The metal-resin composite as claimed in claim 9 , wherein the diameter of the micro-pores is about 1 μm to about 50 μm.

13 . A method for making a metal-resin composite comprising:
providing a metal member; forming a shield layer on the metal member; forming a plurality of holes on the shield layer, the metal member being exposed from the holes; forming a plurality of metal posts in the holes; the shield layer being removed from the surface of the metal member; and liquid resin being filled into spaces between adjacent metal posts and covering the surface of the metal member to bond with the metal member.

14 . The method as claimed in claim 13 , wherein the method for making a metal-resin composite further includes a step of forming a plurality of metal lugs correspondingly on ends of the metal posts away from the metal member, the thickness of each metal lug is about 4 μm to about 8 μm, the resin member is filled the spaces between adjacent metal posts and covers the surface of the metal member and the metal lugs to bond with the metal member.

Assignees

• Shenzhen Futaihong Prec Ind Co
• Fih Hong Kong Ltd

Inventors

• Chiang Chwan-Hwa
• Wang Chieh-Hsiang
• Zhang Bao-Shen

Classifications

• B29C37/0082

  Mechanical anchoring (B29C66/303 takes precedence) · CPC title

• C25D5/48

  After-treatment of electroplated surfaces · CPC title

• C23C18/1607

  by direct patterning · CPC title

• B29L2009/003

  comprising a metal layer · CPC title

• B29K2705/00

  Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts · CPC title