Method of preparing aluminum alloy resin composite and aluminum alloy-resin composite obtainable by the same

Patent metadata

Field	Value
Publication number	US-9809895-B2
Application number	US-201414466906-A
Country	US
Kind code	B2
Filing date	Aug 22, 2014
Priority date	Feb 24, 2012
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

Abstract

A method of preparing aluminum alloy-resin composite and an aluminum alloy-resin composite obtained by the same are provided. of the method comprises: S1: anodizing a surface of an aluminum alloy substrate to form an oxide layer on the surface, the oxide layer including nanopores; S2: immersing the resulting aluminum alloy substrate obtained in step S1 in a buffer solution having a pH of about 10 to about 13, to form a corrosion pores on an outer surface of the oxide layer; and S3: injection molding a resin onto the surface of the resulting aluminum alloy substrate obtained in step S2 in a mold to obtain the aluminum alloy-resin composite.

First claim

What is claimed is:

1. A method of preparing an aluminum alloy-resin composite, comprising:
S1: anodizing a surface of an aluminum alloy substrate to form an oxide layer on the surface, the oxide layer including nanopores;
S2: immersing the resulting aluminum alloy substrate obtained at step S1 in a buffer solution having a pH of about 10 to about 13, to form corrosion pores on an outer surface of the oxide layer and form a double-layer pore structure including the corrosion pores and the nanopores, wherein the corrosion pores have a larger diameter than the nanopores, the corrosion pores have an average diameter of about 200 nm to about 2000 nm, and the corrosion pores are in communication with the nanopores; and
S3: injection molding a resin onto the surface of the resulting aluminum alloy substrate obtained in step S2 in a mold to obtain the aluminum alloy-resin composite.

2. The method according to claim 1 , wherein step S2 comprises repeatedly immersing the resulting aluminum alloy obtained in step S1 in a buffer solution having a pH of about 10 to about 13 for more than one times, wherein each immersing lasts for about 1 min to about 60 minutes, and cleaning the aluminum alloy with water after each immersing.

3. The method according to claim 2 , wherein step S2 comprises repeatedly immersing the resulting aluminum alloy in step S1 in a buffer solution having a pH of about 10 to about 13 for about 2-10 times.

4. The method according to claim 1 , wherein the nanopores have an average diameter of about 10 to about 100 nm; the corrosion pores have an average diameter of about 200 nm to about 2000 nm; and the oxide layer has a thickness of about 1 μm to about 5 μm.

5. The method according to claim 1 , wherein anodizing the surface of the aluminum alloy substrate comprises:
providing the aluminum alloy substrate as an anode in a H 2 SO 4 solution with a concentration of about 10 wt % to about 30 wt %; and
electrolyzing the aluminum alloy substrate at a temperature of about 10° C. to about 30° C. at a voltage of about 10V to about 20V for about 1 min to about 40 min to form the oxide layer with a thickness of about 1 μm to about 10 μm on the surface of the aluminum alloy substrate.

6. The method according to claim 1 , further comprising applying a pretreatment to the aluminum alloy substrate, wherein, the pretreatment includes: oil removal, a first washing with water, alkali etching, a second washing with water, neutralizing, and a third washing with water.

7. The method according to claim 1 , wherein the resin is a thermoplastic resin.

8. A method of preparing an aluminum alloy-resin composite, comprising:
S1: anodizing a surface of an aluminum alloy substrate to form an oxide layer on the surface, the oxide layer including nanopores;
S2: immersing the resulting aluminum alloy substrate obtained at step S1 in a buffer solution having a pH of about 10 to about 13, to form corrosion pores on an outer surface of the oxide layer and form a double-layer pore structure including the corrosion pores and the nanopores, the corrosion pores being wherein the corrosion pores have a larger diameter than the nanopores; and
S3: injection molding a resin onto the surface of the resulting aluminum alloy substrate obtained in step S2 in a mold to obtain the aluminum alloy-resin composite,
wherein the buffer solution comprises a soluble alkali and a soluble dihydrogen phosphate.

9. The method according to claim 8 , wherein the dihydrogen phosphate includes at least one selected from a group of sodium dihydrogen phosphate, potassium dihydrogen phosphate, ammonium dihydrogen phosphate, and aluminum dihydrogen phosphate; the soluble alkali includes at least one selected from a group of sodium hydroxide and potassium hydroxide.

10. The method according to claim 9 , wherein, in the buffer solution, the dihydrogen phosphate has a concentration of about 50 wt % to about 99 wt %, and the soluble alkali has a concentration of about 1 wt % to about 50 wt %.

11. The method according to claim 10 , wherein, in the buffer solution, the dihydrogen phosphate has a concentration of about 60 wt % to about 99 wt %, and the soluble alkali has a concentration of about 1 wt % to about 40 wt %.

12. A method of preparing an aluminum alloy-resin composite, comprising:
S1: anodizing a surface of an aluminum alloy substrate to form an oxide layer on the surface, the oxide layer including nanopores;
S2: immersing the resulting aluminum alloy substrate obtained at step S1 in a buffer solution having a pH of about 10 to about 13, to form corrosion pores on an outer surface of the oxide layer and form a double-layer pore structure including the corrosion pores and the nanopores, the corrosion pores being in communication with the nanopores, wherein the corrosion pores have an average diameter of about 200 nm and the corrosion pores have a larger diameter than the nanopores; and
S3: injection molding a resin onto the surface of the resulting aluminum alloy substrate obtained in step S2 in a mold to obtain the aluminum alloy-resin composite,
wherein the resin is a thermoplastic resin, and
wherein the thermoplastic resin includes a main resin and a polyolefin resin.

13. The method according to claim 12 , wherein the main resin includes polyphenylene ether and polyphenylene sulfide, and the polyolefin resin has a melting point of about 65° C. to about 105° C.

14. The method according to claim 13 , wherein in the main resin, the weight ratio of polyphenylene ether to polyphenylene sulfide is about 3:1 to about 1:3.

15. The method according to claim 12 , wherein the main resin includes polyphenylene oxide and polyamide, and the polyolefin resin has a melting point of about 65° C. to about 105° C.

16. The method according to claim 15 , wherein in the main resin, the weight ratio of polyphenylene oxide to polyamide is about 3:1 to about 1:3.

17. The method according to claim 12 , wherein the main resin includes polycarbonate, and the polyolefin resin has a melting point of about 65° C. to about 105° C.

18. The method according to claim 12 , wherein based on 100 weight parts of the thermoplastic resin, the amount of the main resin is about 70 weight parts to about 95 weight parts, and the amount of the polyolefin resin is about 5 weight parts to about 30 weight parts.

19. The method according to claim 12 ,
wherein based on 100 weight parts of the thermoplastic resin, the thermoplastic resin includes a flow improver with about 1 weight part to about 5 weight parts; and wherein the flow improver includes a cyclic polyester.

Assignees

• Byd Co Ltd
• Shenzhen Byd Auto R&D Co Ltd

Inventors

• Sun Jian
• Wu Yanqin
• Guo Qiang
• Chen Liang

Classifications

• B32B27/365

  comprising polycarbonates · CPC title

• B32B15/20

  comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)} · CPC title

• B29K2705/02

  Aluminium · CPC title

• C25D11/18

  After-treatment, e.g. pore-sealing · CPC title

• B32B2509/00

  Household appliances · CPC title