Resin molded article, and manufacturing method for same

Patent metadata

Field	Value
Publication number	US-2016336199-A1
Application number	US-201515107679-A
Country	US
Kind code	A1
Filing date	Feb 23, 2015
Priority date	Feb 27, 2014
Publication date	Nov 17, 2016
Grant date	—

Abstract

A surface boundary is formed between a sealed surface of a thermosetting resin member and a thermoplastic resin member to seal the sealed surface. A newly formed surface is formed at the surface boundary by removing a surface layer in the sealed surface. A functional group in the newly formed surface is chemically bound to a functional group in a functional group-containing additive added to a constituent material of the thermoplastic resin member.

First claim

1 . A manufacturing method of a resin molded article including:
a thermosetting resin member made of thermosetting resin; and a thermoplastic resin member made of thermoplastic resin to seal a sealed surface as part of a surface of the thermosetting resin member, wherein an exposed surface as a remaining part of the surface of the thermosetting resin member is exposed from the thermoplastic resin member, the manufacturing method comprising: a hardening mold process that uses a thermosetting resin material as a raw material of the thermosetting resin member, and heats and completely hardens the thermosetting resin material to form the thermosetting resin member; a surface layer removal process that removes a surface layer on a topmost surface in at least part of the sealed surface of the thermosetting resin member and forms the at least part of the sealed surface as a newly formed surface containing a functional group; and a plasticizing mold process that
injection-molds a material serving as a thermoplastic resin material as a raw material of the thermoplastic resin member onto the thermosetting resin member formed with the newly formed surface, the material doped with a functional group-containing additive containing a functional group chemically bound to the functional group on the newly formed surface, and
seals the sealed surface of the thermosetting resin member with the thermoplastic resin member while chemically binding the functional group on the newly formed surface to the functional group in the functional group-containing additive with which the thermoplastic resin material is doped.

2 . The resin molded article manufacturing method according to claim 1 ,
wherein the surface layer removal process applies laser irradiation onto the at least part of the sealed surface of the thermosetting resin member.

3 . The resin molded article manufacturing method according to claim 1 ,
wherein: the hardening mold process uses a material containing at least one of a hydroxyl group and an epoxide group as a functional group so that the material is provided as a constituent material of the thermosetting resin member; and the plasticizing mold process uses a material containing at least one of a hydroxyl group, an epoxide group, an amino group, and a carbonyl group as a functional group so that the material is provided as a constituent material of the functional group-containing additive.

4 . The resin molded article manufacturing method according to claim 1 ,
wherein: the hardening mold process uses a material containing at least one of a hydroxyl group and an epoxide group as a functional group so that the material is provided as a constituent material of the thermosetting resin member; and the plasticizing mold process uses the functional group-containing additive whose constituent material contains at least one functional group equal to a functional group contained in a constituent material of the thermosetting resin member to covalently bind to a functional group contained in a constituent material of the thermosetting resin member.

5 . A resin molded article comprising:
a thermosetting resin member made of thermosetting resin; and a thermoplastic resin member made of thermoplastic resin to seal a sealed surface as part of a surface of the thermosetting resin member, wherein: an exposed surface as a remaining part of the surface of the thermosetting resin member is exposed from the thermoplastic resin member; the thermoplastic resin member is doped with a functional group-containing additive containing a functional group; a roughened surface rougher than the exposed surface is formed on the sealed surface of the thermosetting resin member; and a functional group on the roughened surface is chemically bound to the functional group in the functional group-containing additive.

6 . The resin molded article according to claim 5 , further comprising:
a sealed component having one part that is coated with the thermosetting resin member and a remaining part that is protruding from the sealed surface of the thermosetting resin member, wherein: the remaining part of the sealed component is sealed with the thermoplastic resin member; and the roughened surface is provided to the sealed surface located between the exposed surface and the remaining part of the sealed component of the thermosetting resin member to form a closed-ring shape around the remaining part of the sealed component.

7 . A resin molded article comprising:
a thermosetting resin member that is made of a thermosetting resin material and contains a sealed surface as part of a surface and an exposed surface as a remaining part of the surface; and a thermoplastic resin member that is made of a thermoplastic resin material and seals the sealed surface so as to expose the exposed surface belonging to a surface of the thermosetting resin member, wherein: the thermoplastic resin member is partially pushed out along the exposed surface at a boundary between the sealed surface and the exposed surface of the thermosetting resin member to form a resin burr; and a base of the resin burr at least on the exposed surface belonging to a surface of the thermosetting resin member is formed as a surface-processed portion to which surface treatment is applied to increase adhesiveness to the thermoplastic resin member compared to any other part of the surface except the base.

8 . The resin molded article according to claim 7 ,
wherein the sealed surface belonging to a surface of the thermosetting resin member is also formed as the surface-processed portion.

9 . The resin molded article according to claim 7 ,
wherein the thermosetting resin member further includes a protrusion formed at a portion that is included in the base of the resin burr on the exposed surface and is adjacent to the sealed surface so that the protrusion prevents an extension distance of the resin burr toward the exposed surface from the sealed surface.

10 . The resin molded article according to claim 7 ,
wherein the surface-processed portion is formed as a roughened surface that is rougher than any other part of a surface of the thermosetting resin member except the surface-processed portion.

11 . The resin molded article according to claim 7 ,
wherein the thermoplastic resin member is doped with an additive containing a functional group that chemically binds to a functional group in the surface-processed portion of the thermosetting resin member.

12 . A resin molded article manufacturing method to manufacture a resin molded article including:
a thermosetting resin member that is made of a thermosetting resin material and contains a sealed surface as part of a surface and an exposed surface as a remaining part of the surface; and a thermoplastic resin member that is made of a thermoplastic resin material and seals the sealed surface so as to expose the exposed surface belonging to a surface of the thermosetting resin member, wherein the thermoplastic resin member is partially pushed out along the exposed surface at a boundary between the sealed surface and the exposed surface of the thermosetting resin member to form a resin burr, the resin molded article manufacturing method comprising: a preparation process that prepares the thermosetting resin member; and a resin molding process that
uses a die to form the thermoplastic resin member, the die including a molding portion and a fitting portion wherein the molding portion includes a cavity whose spatial configuration corresponds to an external shape of the thermoplastic resin member and wherein the fitting portion is provided adjacently to the molding portio

Assignees

• Denso Corp

Inventors

• Harada Tomoyuki
• Izumi Ryosuke
• Yamakawa Hiroyuki

Classifications

• H10W72/5524

  comprising aluminium [Al] · CPC title

• H10W72/5522

  comprising gold [Au] · CPC title

• H10W74/00

  Encapsulations, e.g. protective coatings · CPC title

• H10W74/10

  characterised by their shape or disposition · CPC title

• H10W90/756

  between a chip and a stacked lead frame, conducting package substrate or heat sink · CPC title