The present invention relates to a composite component of clad material and synthetic resin part and manufacturing method of the same.
The method to join a synthetic resin part to metal materials is known to use an insert molding die. Specifically, a part of the metal part made by iron or steel is inserted in the cavity of the die. At this stage, the molten synthetic resin is injected into a cavity. A portion of the metal part is inserted into and is molded in the synthetic resin part of the predetermined shape.
Moreover, the method to join the synthetic resin part to aluminum materials is known to form an anodizing film having a lot of apertures with more than 25 nm in diameter on the surface of the aluminum material, and a part of the synthetic resin is inserted into apertures of the anodizing film by injection molding.
An aspect of the present invention provides a manufacturing method for a composite component of clad material and synthetic resin part comprising the steps of: forming a film by the electrodeposition coating for the whole surface of a clad material having a aluminum material in at least one aspect; removing a portion of the film formed on the surface of the aluminum material; forming an anodizing film on the surface of the aluminum material which exposed by removing a film; and joining a synthetic resin part to the clad material by pouring a part of the synthetic resin part into a lot of apertures of the anodizing film to form a composition component.
Other aspect of the present invention provides a composite component of clad material and synthetic resin part comprising: a clad material superimposed the stainless steel material on the aluminum material; an anodizing film formed in a portion of the aluminum material; a synthetic resin part joined to the clad material by pouring into apertures of the anodizing film.
Preferred embodiments of the present invention will be explained below in detail with reference to the accompanying drawings.
The manufacturing method of the compound component of a clad material and a synthetic resin part is explained with reference to
At first, In step S101, a pretreatment is carried out for a clad material as a processing object. As shown in
In the pretreatment, a surface treatment is carried out for the stainless steel material 2 mainly. The surface treatment of the stainless steel material 2 forms, for example, a pattern by etching on the surface of the stainless steel material 2 and forms a pattern by machine work like the hairline processing. In this case, the surface treatment is carried out for the aluminum material 3 as substitute for the stainless steel material 2, or in addition to the stainless steel material 2.
Then, In step S102, the clad metal 1 is molded as a predetermined shape by press working. In other case, step S101 may be carried out after step S102, and two steps are carried out at the same time. Moreover, only one of step S101 and step S102 may be carried out.
Moreover, In step S103, the whole surface of the clad metal 1 is coated electrodeposition. As shown in
After this, in step S 104, a portion of the coating film 4 formed on the surface of the aluminum material 3 of the clad material 1 is removed. As shown in
Moreover, in step S105, A film for the joining is formed on the clad metal 1. As shown in
Then, in step S106, a synthetic resin part is joined in the region that formed the anodizing film 5. As shown in
Moreover, in step S107, a postprocessing is carried out for the compound component 8. An example of the postprocessing includes the coating of the stainless steel material 2. Moreover, after removing all of the coating film 4 used as a mask, an exposed surface may be coated again. Moreover, after removing the coating film 4 of the stainless material 2 without removing the coating film 4 of the aluminum material 3, an exposed surface may be coated again. In this case, the coating film 4 may be left as decoration.
In this case, this process may finish without Step S107. Moreover, Step S107 may be carried out with processing like step S101.
Then, The details of each process from step S103 to step S106 of
The details of a electrodeposition coating process of step S103 are explained first.
At first, the clad metal 1 is washed with approximately 5% of sodium hydroxide water solutions which heated to 60° C. to remove fat. Also, the clad material 1 is washed with strong alkali liquid to remove fat electrically. After removal of fat, the clad material 1 is washed with water. Then, the clad material 1 is immersed in 5% to 10% of water solution of sulfuric acid and is neutralized. After that, the clad material 1 is washed with water.
In the electrodeposited coating process, the clad metal 1 is immersed in the coating tank that dissolved water-soluble paint. And, the voltage is applied to the water-soluble paint in the coating tank, when an anode is used for the clad material 1 and the cathode is used an aluminum plate or the stainless steel board. Accordingly, coating film 4 consisting of the water-soluble paint is formed on the surface of the clad material 1 by electrodeposition. As shown in
Here, the coating film 4 is used as a mask in a later process. In addition, the coating film 4 is used as a facing of the decoration. For example, water-soluble paint to form the coating film 4 includes the electrodeposition paint of the anionic type.
Moreover, conditions of the electrodeposition coating include for example, the voltage of 50V to 200V for 1 minute to 3 minutes. In this case, the coating film 4 is formed in the thickness of 10 μm to 20 μm.
Then, the details of the process to remove a portion of the coating film 4 of step S104 are explained.
When removing the coating film 4 partly, the laser processing machine may be used. In this process, for example, the laser beam includes a CO2 laser or YAG laser. The laser beam is irradiated on the predetermined surface of the aluminum materials 3 of the clad material 1.
As shown in a schematic view of
Moreover, the laser processing machine moves the irradiation position with predetermined pitch P1 in the second direction d2 from the position that irradiated a laser beam. Here, the second direction d2 is a direction at right angles to the first direction d1. And after moved the potion with predetermined pitch P1, the laser beam is irradiated to the anodized film along the first direction d1 again.
For example, when the laser beam is irradiated sequentially on the coating film 4 from the left of
After that, these processes are repeated, and the coating film 4 is removed to the position for example, in line L1. Accordingly, A opening 4A showing in
For example, the laser processing machine irradiates a CO2 laser at pulse frequency 20 Hz and moves an irradiation position at the speed of 800 mm/m to 1,200 mm/m. When the irradiation width (length in second direction d2) of the laser beam on the surface of the clad material 1 is 0.1 mm, it is preferable for the pitch P1 to be 0.01 mm to 0.2 mm. If pitch P1 is smaller than this range, it will be not effective because the removal of the coating film 4 take time. If the pitch P1 is bigger than this range, bond strength of the synthetic resin part 7 decreases.
Here, the bond strength between the clad material 1 and the synthetic resin examined by the pulling testing machine using the specimen which joined the synthetic resin to the clad material 1. In this case, the size for the junction of the clad material 1 and the synthetic resin assumes 5 mm in a pulling direction, and 10 mm in the direction at right angles to the pulling direction.
Pulling strength of 120 kgf was obtained when the pitch is 0.01 mm. Pulling strength of 100 kgf was obtained when the pitch is 0.1 mm. Pulling strength of 90 kgf was obtained when the pitch is 0.2 mm. In fact, when the pitch P1 is less than twice the irradiation width of the CO2 laser, pulling strength more than 90 kgf is obtained. Moreover, when the pitch P1 is less than the irradiation width of the CO2 laser, pulling strength more than 100 kgf is obtained. When a YAG laser is used in substitution for a CO2 laser, the pulling strength becomes small.
Then, the details of the formation process of a film for joining of step S105 are explained.
At first, removal of fat process and the neutralization process of the clad material 1 are carried out if needed. Then, a phosphoric acid bath is formed using a phosphoric acid water solution of approximately 30% of density and 18° C. to 20° C. The clad material 1 is immersed into the phosphoric acid bath, and the clad material 1 is used as an anode. A cathode is used an aluminum plate or a stainless steel board. Then, for example, the electrolysis by the direct current method is carried out in the range of voltage 35V to 55V for 1 minute to 5 minutes.
Accordingly, as shown in
In this case, a sodium hydroxide bath may be used in substitution for the phosphoric acid bath. In this case, electro bath of approximately 18° C. to 20° C. that reserved a water solution of the sodium hydroxide of 0.2 mol is used. The processing condition is the same as the phosphoric acid water solution. Accordingly, the porous anodizing film 5 which has apertures of approximately 0.5 μm to 1 μm in depth is formed in the region where removed a mask of the coating film 4 on the surface of the aluminum material 3 of the clad material 1. The diameter of apertures 6 formed on the surface of the anodizing film 5 was approximately 30 nm to 50 nm.
In this way, the clad material 1 is washed with the nitric acid water solution after forming the anodizing film 5 by electrobath using the phosphoric acid bath or the sodium hydroxide. And the clad material 1 is dried by a hot wind.
Here, the phosphoric acid bath may form a large aperture in a short time as compared to the sodium hydroxide bath. Moreover, In the case of using the phosphoric acid bath, the anodizing film 5 obtained apertures 6 in 25 nm to 30 nm diameter when shortened time for electrolysis. In this case, it is desirable to carry out the electrolysis on a condition to form diameter of apertures 25 becomes more than 25 nm, and obtain the depth with more than 500 nm of porous layer 5A. If diameter and depth of the apertures 6 in the anodizing film 5 are smaller than this, bond strength of the synthetic resin part 7 may decrease.
Then, step s106, a process to join the synthetic resin part to region formed a film for the joining to the clad material 1 is explained.
An example of the injection molding machine to be used in this process is shown in
The synthetic resin 24 may use various resin such as PP (polypropylene), PE (polyethylene), PBT(polybutylene terephthalate), the ABS (acrylonitrile/butadiene/styrene resin), PPS(polyphenylene sulfide). In this case, in consideration of difference in linear expansion of the aluminum materials 3 and the synthetic resin 24, it is desirable for synthetic resin materials for forming the synthetic resin molding body by injection molding to choose resin having a coefficient of elasticity that can absorb a difference of the linear expansion, preferably less than 10000 Mpa, and having hot water resistance and medicine resistance. Suitable synthetic resin 24 includes olefin-based resin such as PBT and PE, the PP.
When the synthetic resin part 7 is molded, the clad material 1 is placed in space 22 formed by opening the die 21. The clad material 1 is placed in the die 21 so that the anodizing films 5 face to the gate 25. After closed the die 21, molten synthetic resin 24 is injected into the cavity 23 through the gate 25. Accordingly, the molten synthetic resin 24 pressurizes into the cavity 23 and is filled. The molten synthetic resin 24 is poured into a lot of apertures 6 of the anodizing film 5.
The synthetic resin 24 solidifies by cooling the die 21 using a coolant. Thereafter, as shown in
Here, it is preferable for the molding pressure of the injection molding to be more than approximately 700 kg. For example, the temperature of the die 21 set at 80° C. to 150° C., and the molding pressure set at 700 kg to 1,200 kg. In this case, by heating with a heater attached to the die 21, it may become easier to joining with molten synthetic resin 24 and a heated the clad material 1.
Manufacturing the compound component 8 in this way, bond strength was measured as pulling strength using the pulling testing equipment. In the case of forming the anodizing film 5 using the phosphoric acid bath, tensile strength of 30 kgf obtained with the minimum. Moreover, In the case of forming the anodizing film 5 using the sodium hydroxide bath, tensile strength of 20 kgf obtained with the minimum.
The compound component 8 manufactured in this way obtained a texture of the material of stainless steel on the surface, and enough strength. Moreover, the compound component 8 is lighter by compounding the aluminum materials 3.
As explained in the above, according to the present embodiment, by masking a region which is not joined to the synthetic resin part 7 with the coating film 4, the anodizing film 5 may be formed while protecting the stainless steel material 3. With the case which exposed the stainless steel material 3, a current density becomes higher, and the stainless steel material 3 may receive damage, but the stainless steel material 3 is protected with the painting film 4 by this manufacturing method. Moreover, work efficiency is improved by masking only a desired region of the painting film 4 to form the anodizing film 5.
Furthermore, a desired region is easily processed by using a laser beam to remove a portion of the coating film 4. It may accept easily for changing the size and the shape of a region removing the coating film 4. In here, the coating film 4 is removed well by irradiating the laser beam in a pitch of 0.01 mm to 0.2 mm. Therefore, the synthetic resin part 7 is joined strongly.
And, the compound component 8 is easily manufactured using usual process by joining the synthetic resin part 7 to the clad metal 1 using the anodizing film 5.
Here, the compound component 8 may use for a cell-phone and an information terminal, the case of the camera, e.g., a removable cover. The example of the compound component 8 manufactured as a cover of the case of the cell-phone is shown in
The Synthetic resin part 33, 35 are joined to the aluminum materials 3 of the clad material 1 by a method same as the synthetic resin part 7 according to flow chart shown in
As the cover 30 shown in
Moreover, the rigidity for the mount portion of cover 30 is lowered by using the synthetic resin part 33, 35. Accordingly, Even if the cover 30 put to and take off the case body 36 many times, durability for the mount portion may improve. Here, in the case that mount potion manufactured with the stainless steel material 2 together, plural dies are necessary to press the complicated shape for the mount portion. Therefore, production cost rises.
Moreover, the mount portion forms together with the clad material 1 using press working, stress may concentrate on the clad metal 1 connecting the mount portion and be deform the clad metal 1. In this embodiment, a problem is solved because synthetic resin part 33, 35 is used for the mount portion.
In this case, the clad material 1 may has the structure that superimposed different metal materials other than the stainless steel material 2 on the aluminum material 3. Moreover, the clad material 1 may have a stricture that superimposed a duralumin material on other aluminum material, and put a duralumin material between aluminum materials.
The second embodiment of the manufacturing method of the compound component of a clad material and the synthetic resin part will be concretely described with referent to
In step S201, a clad material 1 is preprocessed first. This process is similar to the first enforcement. Then, in step S202, a partial mask is formed on the surface of the clad material 1 by print. As shown in
Then, in step S203, the clad material 1 is pressed in a similar process of the first embodiment. Moreover, in step S204, masking is carried out by the electrodeposition coating. The electrodeposition coating is carried out for the whole surface of the clad material 1, and homogeneous coating film 4 is formed. This process is carried out in a similar process of the first embodiment. In this case, as shown in
After this, in step S205, the partial mask 41 is removed with an ink remover. The ink remover is used, for example, a non-chlorine-based solvent, which dissolve the partial mask 41, but does not dissolve the coating film 4.
When only the partial mask 41 removed the surface of the aluminum material 3, the aluminum material 3 of the region where the partial mask 41 was formed is exposed. As a result, the opening 4A that is similar to
Then, in step 206, the anodizing film 5 is formed in the region where the aluminum material 3 was exposed to by removing the partial mask 41 as a film for joining. Moreover, in step S207, the Synthetic resin part 7 is joined on the anodizing film 5. These processes are carried out in a similar process of the first embodiment.
Accordingly, as shown in
As explained in the above, according to the present embodiment, by removing painting film 4 partially by forming the partial mask 41, the region joining the synthetic resin part 7 is defined only by medicinal solution process.
According to the present embodiment, in step S106 or step S207, the clad material 1 and the synthetic resin part 7 are made separately, and the compound component 8 is made by joining both materials by a heating crimp method.
The induction heating device 52 has a bottom portion 55A of a holder 55 containing the clad material 1, and a coil 56 for plane heating is buried in a bottom portion 55A. The coil 56 is connected to a high frequency oscillator 57 provided outward.
When joining the synthetic resin part 7, the clad material 1 is contained in holder 55 at first. The clad metal 1 is placed in holder 55 so that a surface of the anodizing film faces the top. Furthermore, the synthetic resin part 7 is put on the joining position of the anodizing film 5.
Then, going down the press head 53, the Synthetic resin part 7 is pressurized from the upper portion and is pushed to the anodizing film 5. From this point, applying current to the coil 56 by operation of the high frequency oscillator 57, the clad material 1 is heated by induction heating.
Accordingly, the synthetic resin part 7 is heated through contact with the clad material 1, and the potion of the synthetic resin which is pushed to an anodizing film 5 melts and pours into apertures 6 of the anodizing film 5. After cooling the clad material 1 and the synthetic resin part 7, going up the press head 53. The compound component 8 is obtained from the synthetic resin part 7 joined to the clad material 1 through the anodizing film 5.
Here, with this production apparatus 51, the compound component 8 of enough bond strength is provided by the high frequency output of high frequency oscillator 57 at 500 W to 50 kW, frequency 50 kHz to 3 MHz for 10 seconds to 12 seconds, for example.
In this case, the characteristic of the embodiments is added below.
According to the clad material and the manufacturing method of the compound component of the synthetic resin part, the anodizing film is formed only in a part of the aluminum material side of the clad material. The part consisting of the material except the aluminum material is protected with a film. By medicinal solution and an electric current for forming the anodizing film, the portion of the materials except the aluminum material does not catch the damage.
Moreover, a CO2 laser removes only a irradiated portion of the film. The film is removed more precisely by making smaller the pitch of irradiating a laser beam. The anodizing film may be formed reliably.
Moreover, According to the clad material and the manufacturing method of the compound component of the synthetic resin part, a portion of the film may be removed only by medicinal solution processing. Other domains covered by a film are protected reliably by dissolving only a partial mask.
As the aperture diameter of the anodizing film becomes big, joint strength of the synthetic resin part may increases.
A molten synthetic resin may join the synthetic resin part which poured into the apertures of the anodizing film by using injection molding. A synthetic resin part melts partially and pours into the apertures of the anodizing film at the contact surface between the anodizing film and the synthetic resin part. Accordingly, the synthetic resin part is joined to the clad material. While having texture of the material and the strength of stainless steel material, the synthetic resin part may obtain lighter body using the aluminum material.
According to the clad material and the compound component of the synthetic resin part, texture of the material and the strength of stainless steel material are provided by using the stainless steel material for outer surface. By using the aluminum material for the inner surface to obtain lighter body and may join the synthetic resin part using the aluminum material. The synthetic resin part may engage to other parts and use for a spacer.
According to the clad material and the compound component of the synthetic resin part, the synthetic resin part is attached to other parts by engaging the synthetic resin part to other parts.
In this case, the compound part of embodiments may be apply to the clad material and the composition product having various kinds of size and shapes such as the personal ornaments such as an outside device product, the number plate among the electric apparatuses such as a personal computer or the cell-phone, parts such as the electronic equipment, building materials, the indoor of the building, an outside device product, a ship, a plane, a railroad carriage and cars with the synthetic resin part.
This invention is interpreted without being limited to an example and the condition of embodiments.
As for this invention, various kinds of changes and transformation are possible in the range that does not deviate from the spirit and scope.
Number | Date | Country | Kind |
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2009-021437 | Feb 2009 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2010/051241 | 1/29/2010 | WO | 00 | 8/2/2011 |