Metal-resin composite body

Patent metadata

Field	Value
Publication number	US-2016303820-A1
Application number	US-201415103715-A
Country	US
Kind code	A1
Filing date	Nov 28, 2014
Priority date	Dec 13, 2013
Publication date	Oct 20, 2016
Grant date	—

Abstract

A metal-resin composite body ( 100 ) of the present invention is obtained by bonding a resin member ( 101 ) and a metal member ( 102 ) together. The resin member ( 101 ) is obtained by curing a thermosetting resin composition (P) containing a thermosetting resin (A) and a filler (B). The metal member ( 102 ) has a roughened layer ( 104 ) including fine irregularities on at least a bonding surface ( 103 ) bonded to the resin member ( 101 ). A portion of the filler (B) is present in depression portions constituting the irregularities of the roughened layer ( 104 ).

First claim

1 . A metal-resin composite body obtained by bonding a resin member and a metal member together,
wherein the resin member is obtained by curing a thermosetting resin composition containing a thermosetting resin and a filler,
the metal member has a roughened layer including fine irregularities on at least a bonding surface bonded to the resin member, and,
a portion of the filler is present in depression portions constituting the irregularities of the roughened layer.

2 . The metal-resin composite body according to claim 1 ,
wherein each of the depression portions has such a sectional shape that, between an opening portion and a bottom portion of the depression portion, there is at least a portion whose section width is greater than a section width of the opening portion.

3 . The metal-resin composite body according to claim 1 ,
wherein an average aspect ratio of the filler present in the depression portion is equal to or greater than 1 and equal to or less than 50.

4 . The metal-resin composite body according to claim 1 ,
wherein an average major axis length of the filler present in the depression portion that is determined through image analysis performed on an electron micrograph is equal to or greater than 0.1 μm and equal to or less than 5.0 μm.

5 . The metal-resin composite body according to claim 1 ,
wherein the filler present in the depression portion is one kind of filler or two or more kinds of filler selected from the group consisting of wollastonite, kaolin clay, talc, calcium carbonate, zinc oxide, calcium silicate hydrate, aluminum borate whiskers, and potassium titanate fiber.

6 . The metal-resin composite body according to claim 1 ,
wherein an average section width of the opening portion of the depression portion is equal to or greater than 2 μm and equal to or less than 60 μm.

7 . The metal-resin composite body according to claim 1 ,
wherein an average depth of the depression portion is equal to or greater than 0.5 μm and equal to or less than 40 μm.

8 . The metal-resin composite body according to claim 1 ,
wherein a thickness of the roughened layer is within a range of equal to or greater than 3 μm and equal to or less than 40 μm.

9 . The metal-resin composite body according to claim 1 ,
wherein when the total content of the resin member is 100% by mass, the content of the filler is equal to or greater than 30% by mass and equal to or less than 80% by mass.

10 . The metal-resin composite body according to claim 9 ,
wherein when the total content of the filler is 100% by mass, the resin member contains a filler whose average particle size in a weight-based particle size distribution measured by a laser diffraction and scattering-type particle size distribution analysis method is equal to or greater than 0.1 μm and equal to or less than 5 μm, in an amount of equal to or greater than 1% by mass and equal to or less than 30% by mass.

11 . The metal-resin composite body according to claim 1 ,
wherein the thermosetting resin is a phenol resin.

12 . The metal-resin composite body according to claim 11 ,
wherein the phenol resin is one kind of resin or two or more kinds of resin selected from the group consisting of a novolac-type phenol resin, a resol-type phenol resin, and an arylalkylene-type phenol resin.

13 . The metal-resin composite body according to claim 1 ,
wherein the resin member further contains an elastomer.

14 . The metal-resin composite body according to claim 13 ,
wherein the resin member has a sea-island structure, and
the elastomer is present in island phases.

15 . The metal-resin composite body according to claim 14 ,
wherein the average diameter of the island phases that is determined through image analysis performed on an electron micrograph is equal to or greater than 0.1 μm and equal to or less than 100 μm.

16 . The metal-resin composite body according to claim 13 ,
wherein the elastomer is one kind of elastomer or two or more kinds of elastomer selected from the group consisting of unmodified polyvinyl acetate, polyvinyl acetate modified with carboxylic acid, polyvinyl butyral, natural rubber, isoprene rubber, styrene butadiene rubber, butadiene rubber, chloroprene rubber, butyl rubber, ethylene propylene rubber, acryl rubber, styrene isoprene rubber, acrylonitrile butadiene rubber, urethane rubber, silicon rubber, and fluorine rubber.

17 . The metal-resin composite body according to claim 1 ,
wherein when the thermosetting resin composition is heated to become to a melted state from 60° C. at a heating rate of 3° C./min and a frequency of 1 Hz by using a dynamic viscoelasticity measurement instrument, the melt viscosity of the composition decreases during the initial stage but increases after the composition reaches the lowest melt viscosity, and
the lowest melt viscosity is within a range of equal to or greater than 10 Pa·s and equal to or less than 2,000 Pa·s.

18 . The metal-resin composite body according to claim 17 ,
wherein the temperature at which the thermosetting resin composition reaches the lowest melt viscosity is equal to or higher than 100° C. and equal to or lower than 250° C.

19 . The metal-resin composite body according to claim 1 ,
wherein the metal member is formed of one kind of metal or two or more kinds of metal selected from the group consisting of steel, stainless steel, aluminum, an aluminum alloy, magnesium, a magnesium alloy, copper, and a copper alloy.

20 . The metal-resin composite body according to claim 1 that is obtained by curing the thermosetting resin composition by a molding method selected from an injection molding method, a transfer molding method, a compression molding method, and an injection and compression molding method in a state where at least a portion of the thermosetting resin composition comes into contact with the bonding surface of the metal member.

Assignees

• Sumitomo Bakelite Co

Inventors

• Takihana Yoshihiro
• Koizumi Koji
• Watanabe Yusuke

Classifications

• C23F1/36

  for etching aluminium or alloys thereof · CPC title

• C23F1/20

  for etching aluminium or alloys thereof · CPC title

• B32B2270/00

  Resin or rubber layer containing a blend of at least two different polymers · CPC title

• B32B2264/104

  Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles · CPC title

• B32B2264/102

  Oxide or hydroxide · CPC title