WO2010087439A1 - Composite component of cladding material and synthetic resin part and manufacturing method therefor - Google Patents

Abstract

In a laminated cladding material (1) of stainless steel (2) and aluminum (3), a coating film (4) is formed by electrodeposition coating the entire surface of each of the stainless steel (2) and the aluminum (3). A portion of the coating film (4) on the aluminum (3) is then removed by laser irradiation to expose the aluminum (3) in this area. An anodic oxide coating (5) is formed on the exposed aluminum (3), which is then introduced into an injection molding machine and a synthetic resin part (7) is formed while pores (6) in the anodic oxide coating (5) are impregnated with synthetic resin. In this way, a composite component (8) of the cladding material (1) and the synthetic resin part (7) is manufactured.

Description

Composite product of clad material and synthetic resin part and manufacturing method thereof

The present invention relates to a composite product of a clad material in which a synthetic resin molded body is joined to an aluminum material and a synthetic resin part, and a method for manufacturing the same.

It is known to use a mold for insert molding as a method of joining a synthetic resin part to a metal material. Specifically, a part of a metal part made of iron or steel is inserted into the cavity of the mold, the synthetic resin melted in this state is injected into the cavity, and the metal part is inserted into the synthetic resin part of a predetermined shape. Part of the insert is molded.

In addition, as a method of joining a synthetic resin component to an aluminum material, an anodized film having a large number of holes having a diameter of 25 nm or more is formed on the surface of the aluminum material, and a part of the synthetic resin is formed by injection molding or the like. It is known to bite into the holes.

International Publication No. 2004/055248 Specification

Here, a clad material in which a plurality of metal plates are overlapped may be used for a metal exterior part in order to obtain a metal texture or to secure weight reduction and strength. Therefore, it has been desired to be able to join synthetic resin parts to the clad material.

The present invention has been made in view of such circumstances, and a main object of the present invention is to enable efficient production of synthetic resin parts on a clad material having an aluminum material.

According to one aspect of the present invention, a step of forming a film by electrodeposition coating on the entire surface of a clad material provided with an aluminum material on at least one surface, and the film formed on the surface of the aluminum material A part of the resin material, a step of forming an anodized film on the surface of the aluminum material exposed by removing the film, and a part of the synthetic resin part in a large number of holes of the anodized film. There is provided a method of manufacturing a composite product of a clad material and a synthetic resin part, comprising the step of joining the clad material and the synthetic resin part to form a composite product by intrusion.

According to another aspect of the present invention, there is provided a method for producing a composite product of a clad material and a synthetic resin part, wherein the step of removing a part of the coating is a step of removing the coating by irradiation with a CO ₂ laser. The

According to another aspect of the present invention, the laser beam is irradiated in a line in a first direction, and the laser beam is irradiated in a second direction substantially perpendicular to the first direction from 0.01 mm to 0.00 mm. Provided is a method for producing a composite product of a clad material and a synthetic resin part that removes the film while feeding at a pitch of 2 mm.

According to another aspect of the present invention, after a partial mask is formed on a part of the surface of the aluminum material, a coating film is formed on the entire surface of the cladding material including the top of the partial mask in the step of forming a film by the electrodeposition coating. In the step of forming the film and removing a part of the film, a method of manufacturing a composite product of a clad material and a synthetic resin component is provided, in which the partial mask is dissolved to remove a part of the film.

According to another aspect of the present invention, there is provided a method for producing a composite product of a clad material having a large number of holes having a diameter of 40 nm to 100 nm and a synthetic resin part.

According to another aspect of the present invention, there is provided a method for manufacturing a composite product of a clad material formed by injection molding and a synthetic resin component.

According to another aspect of the present invention, there is provided a method for manufacturing a composite product of a clad material and a synthetic resin component that are pressed against and bonded to the anodized film while heating the synthetic resin component.

According to another aspect of the present invention, there is provided a method for manufacturing a composite product of a clad material, which is a clad material obtained by superposing a stainless steel on the aluminum material, and a synthetic resin part.

Further, according to another aspect of the present invention, a clad material in which an aluminum material is superimposed on a stainless material, an anodized film formed on a part of the aluminum material, and a part of the hole in the anodized film A composite product of a clad material and a synthetic resin part including a synthetic resin part joined to the clad material by intrusion is provided.

According to another aspect of the present invention, the anodic oxide film is formed on a peripheral portion of the clad material, and the resin member is a clad material used for engaging the clad material with other parts. And synthetic resin parts are provided.

The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

The foregoing general description and the following detailed description are for purposes of illustration only and are not intended to limit the invention.

According to the present invention, since the anodized film is formed at a predetermined position of the aluminum material of the clad material, the synthetic resin component can be formed using the anodized film while protecting the metal on the surface to which the synthetic resin component is not joined. Can be joined to clad material.

FIG. 1 is a flowchart of a method for manufacturing a composite product of a clad material and a synthetic resin component according to the first embodiment of the present invention. FIG. 2 is a cross-sectional view of the clad material. FIG. 3 is a cross-sectional view illustrating a process of forming a coating layer on the entire surface of the clad material. FIG. 4 is a cross-sectional view illustrating a process of removing a part of the coating layer by laser irradiation. FIG. 5 is a plan view showing an example of a clad material when a part of the coating layer is removed by laser irradiation. FIG. 6 is a cross-sectional view illustrating a process of forming an anodic oxide film in the region from which the coating layer has been removed. FIG. 7 is a plan view of a clad material on which an anodized film is formed. FIG. 8 is a cross-sectional view illustrating a process of molding a synthetic resin part on the anodized film. FIG. 9 is a plan view of a composite product manufactured by molding a synthetic resin part on a clad material. FIG. 10 is a diagram schematically showing the locus of laser irradiation. FIG. 11 is a cross-sectional view of the injection molding machine. FIG. 12 is a plan view of a cover which is an example of a composite product. FIG. 13 is a cross-sectional view taken along the line II of FIG. FIG. 14 is a flowchart of a method for manufacturing a composite product of a clad material and a synthetic resin part according to the second embodiment of the present invention. FIG. 15 is a plan view showing an example of a clad material on which a partial mask is formed. 16 is a cross-sectional view taken along line II-II in FIG. FIG. 17 is a cross-sectional view illustrating a process of forming a coating film by electrodeposition coating on the entire surface of the cladding material including on the partial mask. FIG. 18 is a plan view of a composite product manufactured by molding a synthetic resin part in the region where the partial mask is removed. FIG. 19 is a cross-sectional view of an apparatus for joining a synthetic resin component to a clad material by a thermocompression bonding method.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the drawings, similar components are given the same reference numerals. Moreover, in each embodiment, the overlapping description is abbreviate | omitted.

(First embodiment)
First, an outline of a method for manufacturing a composite product of a clad material and a synthetic resin part will be described with reference to FIG.

First, in step S101, a pretreatment process is performed on a clad material that is a workpiece. As shown in FIG. 2, the clad material 1 is integrated by superposing an aluminum material 3 on a stainless steel material 2. For example, the thickness of the stainless steel material 2 is about 0.2 mm to 0.4 mm, and the thickness of the aluminum material 3 is about 0.1 mm to 0.2 mm.

In the pretreatment process, surface treatment is mainly performed on the stainless steel material 2. Examples of the surface treatment of the stainless steel material 2 include forming a pattern on the surface of the stainless steel material 2 by etching or forming a pattern by machining such as hairline processing. Instead of or in addition to the pretreatment for the stainless steel material 2, a surface treatment may be applied to the aluminum material 3 side.

Next, in step S102, the clad material 1 is pressed and formed into a predetermined shape. Note that the order of step S101 and step S102 may be reversed, or two steps may be performed simultaneously. Moreover, you may implement only one of step S101 and step S102.

Furthermore, in step S103, electrodeposition coating is performed on the entire surface of the clad material 1. As shown in FIG. 3, a uniform coating film 4 is formed on the surface of the clad material 1 by electrodeposition coating. The coating film 4 is used as a mask in a later process.

Thereafter, in step S104, a part of the coating film 4 formed on the surface of the aluminum material 3 among the surface of the clad material 1 is removed. As shown in FIG.4 and FIG.5, the opening part 4A is formed in the coating film 4, and the aluminum material 3 is exposed through the opening part 4A. In FIG. 5, the coating film 4 on the peripheral edge of the clad material 1 is partially removed, but the location, size, and number of the coating film 4 to be removed are not limited to this.

Further, in step S105, the clad material 1 is formed with a bonding film. As shown in FIGS. 6 and 7, a porous anodic oxide film 5 as a bonding film is formed on the surface of the aluminum material 3 exposed by removing the paint film 4, that is, the region not masked by the paint film 4. It is formed. Here, the anodic oxide film 5 has a porous layer 5A in which elongated holes 6 opening on the surface are densely packed, and a thin dense insulating layer 5B from the bottom of the porous layer 5A to the metal surface. Further, the region where the anodic oxide film 5 is formed coincides with the region where the coating film 4 is removed.

Next, in step S106, the synthetic resin component is joined to the region where the anodized film 5 is formed. As shown in FIGS. 8 and 9, the synthetic resin component 7 is joined to the clad material 1 so as to bite into the holes 6 of the anodic oxide film 5, whereby a composite product 8 of the clad material 1 and the synthetic resin component 7 is formed. It is formed. The synthetic resin component 7 is bonded to the clad material 1 with an area smaller than the area of the anodic oxide film 5, but part of the paint film 4 beyond the same area as the anodic oxide film 5 or beyond the anodic oxide film 5. You may shape | mold so that it may be covered.

Further, in step S107, post-processing is performed on the composite product 8. As an example of the post treatment, there is a coating of the stainless steel material 2. Alternatively, all of the coating film 4 used as a mask may be removed, and a new coating may be performed on the exposed surface. Furthermore, it is also possible to remove only the coating film 4 of the stainless steel material 2 without removing the coating film 4 of the aluminum material 3 and perform a new coating. In addition, you may use the coating film 4 as a decoration as it is.

Note that the processing may be terminated without performing step S107. Further, the same processing as step S101 may be performed together with step S107.

Next, details of each process from step S103 to step S106 in FIG. 1 will be described below.

First, the details of the electrodeposition coating process in step S103 will be described.

First, the clad material 1 is degreased by washing with a warm solution of about 5% sodium hydroxide aqueous solution heated to 60 ° C. Alternatively, electrolytic degreasing is performed on the clad material 1 using a strong alkaline solution. After the degreasing treatment, the clad material 1 is washed with water. Next, the clad material 1 is immersed in a 5% to 10% sulfuric acid aqueous solution for neutralization treatment, and then the clad material 1 is washed with water.

When performing electrodeposition coating, the clad material 1 is immersed in a coating tank in which a water-soluble paint is dissolved. Then, a voltage is applied to the water-soluble paint in the coating tank using the clad material 1 as an anode and an aluminum plate or a stainless steel plate as a cathode. Thereby, the coating film 4 made of a water-soluble paint is formed on the surface of the clad material 1 by electrodeposition. As shown in FIG. 3, the coating film 4 is formed substantially uniformly on each of the exposed surface of the stainless steel material 2 and the exposed surface of the aluminum material 3.

Here, the coating film 4 can be used as a mask in a subsequent process, and can also be used as a finished surface for decoration. Examples of the water-soluble paint for forming such a coating film 4 include an anionic electrodeposition paint.

Also, as a condition for electrodeposition coating, for example, a voltage of 50 V to 200 V is applied for 1 minute to 3 minutes. In this case, the coating film 4 having a film thickness of 10 μm to 20 μm is formed.

Next, details of the process of removing part of the coating film 4 in step S104 will be described.

When part of the coating film 4 is removed, a laser processing machine can be used. Examples of the laser light used in this step include a CO ₂ laser and a YAG laser. The laser beam is applied to a predetermined surface of the clad material 1 on the aluminum material 3 side.

As shown in the schematic diagram of FIG. 10, the laser irradiation is performed on a region where the synthetic resin component 7 is joined later. First, the irradiation position of the laser beam is moved on the coating film 4 in a predetermined first direction d1. Thereby, the coating film 4 is removed linearly.

Further, the irradiation position of the laser beam is moved by a predetermined pitch P1 in the second direction d2 from the portion irradiated with the laser beam. Here, the second direction d2 is a direction substantially orthogonal to the first direction. Then, the coating film 4 is irradiated from the position moved by the predetermined pitch P1 while moving the laser light again in the first direction d1. For example, when laser irradiation is sequentially performed from the left side in FIG. 10 and the coating film 4 is removed to the position indicated by the line BL1, the next laser irradiation position is a position on the line BL2 moved to the right by the pitch P1. . Thereafter, these operations are repeated, and the coating film 4 is removed up to a predetermined region, for example, the position indicated by the line L1. Thereby, an opening 4A as shown in FIG. 7 is formed in the coating film 4, and the aluminum material 3 in this region is exposed.

For example, the laser processing machine moves the irradiation position at a speed of 800 mm / min to 1200 mm / min while outputting a CO ₂ laser at a pulse frequency of 20 Hz. When the irradiation width of laser light on the surface of the clad material 1 (length in the second direction d2) is 0.1 mm, the pitch P1 is preferably 0.01 to 0.2 mm. If the pitch P1 is smaller than this range, it takes too much time to remove the paint film 4, which is not efficient. When the pitch P1 is larger than this range, the joint strength of the synthetic resin component 7 is lowered.

Here, a test piece in which a synthetic resin was bonded to the clad material 1 was produced, and the bonding strength between the clad material 1 and the synthetic resin was examined using a tensile tester. In addition, the magnitude | size of the junction part of the clad material 1 and a synthetic resin was 5 mm in the tension direction, and 10 mm in the direction orthogonal to a tension direction.

When the pitch P1 was 0.01 mm, a tensile strength of 120 kgf was obtained. When the pitch P1 was 0.1 mm, a tensile strength of 100 kgf was obtained. When the pitch P1 was 0.2 mm, a tensile strength of 90 kgf was obtained. That is, when the pitch P1 is less than twice the irradiation width of the CO ₂ laser, a tensile strength of 90 kgf or more can be obtained. Furthermore, when the pitch P1 is set to be equal to or less than the irradiation width of the CO ₂ laser, a tensile strength of 100 kgf or more can be obtained. When a YAG laser is used instead of the CO ₂ laser, the tensile strength is slightly reduced.

Next, the details of the bonding film forming process in step S105 will be described.

First, degreasing treatment and neutralization treatment of the clad material 1 are performed as necessary. Next, the clad material 1 is immersed in a phosphoric acid bath made of a phosphoric acid aqueous solution having a liquid temperature of about 18 to 20 ° C. and a concentration of about 30% to form an anode. An aluminum plate, a stainless steel plate, or the like is used for the cathode. Then, electrolysis by the direct current method is performed in a voltage range of 35 V to 55 V, for example, for 1 minute to 5 minutes.

As a result, as shown in FIG. 6, a porous anodic oxide film 5 having a depth of about 1 μm to 1.5 μm is formed on the surface of the aluminum material 3 of the clad material 1 where the mask of the coating film 4 is removed. Is formed. The diameter of many holes 6 formed on the surface of the anodized film 5 was about 40 nm to 100 nm.

A sodium hydroxide bath may be used instead of the phosphoric acid bath. In this case, an electrolytic bath having a liquid temperature of about 18 to 20 ° C. in which an aqueous solution of 0.2 mol of sodium hydroxide is stored is used. The treatment conditions are the same as when using a phosphoric acid aqueous solution. As a result, a porous anodic oxide film having a number of holes 6 having a depth of 0.5 to 1 μm and a diameter of about 30 to 50 nm in the region where the mask of the coating film 4 is removed on the surface of the aluminum material 3 of the clad material 1. 5 is formed.

Thus, when the anodic oxide film 5 is formed using the phosphoric acid bath or the electrolytic bath using sodium hydroxide, the clad material 1 is washed with a nitric acid aqueous solution and then dried with hot air.

Here, it is possible to obtain pores having a larger pore size in a shorter time in the phosphoric acid bath than in the sodium hydroxide bath. Further, in the example using the phosphoric acid bath, when the electrolysis time was shortened, the anodic oxide film 5 having the diameter of the holes 6 of 25 nm to 30 nm was obtained. The electrolysis is preferably performed under conditions such that the diameter of the holes 25 is 25 nm or more and the porous layer 5A is 500 nm or more deep. If the hole diameter and depth of the anodized film 5 are smaller than this, the joint strength of the synthetic resin component 7 may be lowered.

Next, the process of joining the synthetic resin part to the region where the joining film is formed on the clad material 1 in step S106 will be described.

FIG. 11 shows an example of an injection molding machine used in this process. The injection molding machine 20 has a mold 21 that can be opened and closed vertically, and a space 22 in which the clad material 1 is installed is formed between a lower mold 21A and an upper mold 21B. Further, the upper mold 21B is formed with a cavity 23 that matches the shape of the synthetic resin component 7 and a gate 25 through which the synthetic resin 24 that fills the cavity 23 passes. The gate 25 is connected to a supply source of the synthetic resin 24 (not shown).

As the synthetic resin 24, various resins such as PP (polypropylene), PE (polyethylene), PBT (polybutylene terephthalate), ABS (acrylonitrile / butadiene / styrene resin), PPS (polyphenylene sulfide) can be used. In addition, considering the difference in linear expansion between the aluminum material 3 and the synthetic resin 24 as a synthetic resin material to be a synthetic resin molded body by the above injection molding, an elastic modulus capable of absorbing the difference in linear expansion, preferably 10000 Mpa or less It is preferable to select a resin having an elastic modulus and having hot water resistance and chemical resistance. Suitable synthetic resins 24 include olefinic resins such as PBT, PE, and PP.

When molding the synthetic resin part 7, the mold 21 is opened and the clad material 1 is installed in the space 22. The clad material 1 is disposed so that the anodized film 5 faces upward, that is, the anodized film 5 faces the gate 25. After the mold 21 is closed, the molten synthetic resin 24 is injected from the gate 25 into the cavity 23. As a result, the melted synthetic resin 24 is pressurized and filled into the cavity 23 and enters the numerous holes 6 of the anodized film 5.

In this state, the mold 21 is cooled with cooling water to solidify the synthetic resin. Thereafter, when the mold is opened, a composite product 8 as shown in FIGS. 8 and 9 is obtained. The composite product 8 has a configuration in which the synthetic resin 2 of the synthetic resin component 7 is partially bitten into the numerous holes 6 of the anodized film 5 and joined.

Here, the molding pressure during injection molding is preferably about 700 kg or more. For example, the temperature of the mold 21 is 80 to 150 ° C., and the molding pressure is 700 kg to 1200 kg. If molding is performed while a heater is attached to the mold 21 and the mold 21 is heated, the molten synthetic resin 24 and the heated clad material 1 can be more easily joined.

The joint strength between the clad material 1 and the synthetic resin component 7 in the composite product 8 thus manufactured was measured as a tensile strength using a tensile tester. When the anodic oxide film 5 was formed by a phosphoric acid bath, a tensile strength of 30 kgf was obtained at the minimum. Further, when the anodic oxide film 5 was formed with a sodium hydroxide bath, a tensile strength of 20 kgf was obtained at the minimum.

The composite product 8 manufactured in this way has a stainless steel texture on the surface and sufficient strength. Further, since the aluminum material 3 is combined, the weight of the parts can be reduced.

As described above, in this embodiment, since the region other than the region where the synthetic resin component 7 is joined is masked with the coating film 4, the anodized film 5 is formed while protecting the stainless steel material 3. be able to. If the stainless steel material 3 is exposed, the current density increases and the stainless steel material 3 may be damaged. However, in this manufacturing method, the stainless steel material 3 is protected by the coating film 4. Moreover, since the anodic oxide film 5 is formed only in a necessary region by masking with the coating film 4, the work efficiency is good.

Furthermore, since a laser beam is used in the process of removing a part of the coating film 5, only a necessary area can be easily processed. It is possible to easily cope with changes in the size and shape of the area where the coating film 5 is removed. Here, since the pitch P1 at the time of laser irradiation is set to 0.01 mm to 0.2 mm, the coating film 5 can be sufficiently removed, and the synthetic resin component 7 can be firmly joined.

And since the synthetic resin component 7 was joined to the clad material 1 using the anodic oxide film 5, the composite article 8 can be easily manufactured using the processing actually applied to the aluminum plate. .

Here, the composite product 8 can be used for a mobile phone, an information terminal, a camera case, such as a removable cover. 12 and 13 show an example in which the composite product 8 is manufactured as a cover for a mobile phone case. The cover 30, which is a composite product, has an outer shape obtained by bending the three peripheral portions 31 and 32 of the elongated clad material 1 toward the aluminum material 3, and a synthetic resin is formed on the inner portions of the peripheral portions 31 and 32. The component 33 is joined. The synthetic resin component 33 is integrally formed with a claw 33A protruding inward. Further, two resin members 35 are joined to the remaining one peripheral edge 34 that has not been bent. The two resin members 35 protrude toward the outside of the cover 30 substantially in parallel to the surface of the cover 30 that is not bent.

These synthetic resin parts 33 and 35 are joined to the aluminum material 3 of the clad material 1 in accordance with the flowchart shown in FIG. The cover 30 can be attached to the case body 36 which is another component by fitting the resin members 33 and 35 into the recesses or grooves provided on the case body 36 side.

In the cover 30 as shown in FIG. 12 and FIG. 13, the portion used for attaching to the case main body 36 is manufactured by the synthetic resin parts 33 and 35, so that the rigidity is lowered as compared with the case of manufacturing from a metal material. be able to. For this reason, it becomes easy to attach and remove the cover 30 to the case body 36.

Furthermore, by using the synthetic resin parts 33 and 35, the rigidity of the attachment portion of the cover 30 can be lowered. Thereby, when the cover 30 is attached to and detached from the case main body 36 many times, durability of the attachment portion is improved. Here, when the attachment member is manufactured integrally with the stainless steel material 2, the complicated shape of the attachment portion must be pressed using a plurality of dies, which increases the manufacturing cost. Furthermore, when the attachment portion is formed integrally with the clad material 1 by press working, stress may be concentrated on the clad material 1 connected to the attachment portion to cause deformation. In this embodiment, such a problem can be solved by using the synthetic resin parts 33 and 35 for the attachment portion.

The clad material 1 may have a structure in which a dissimilar metal material other than the stainless steel material 2 is superimposed on the aluminum material 3. Furthermore, the clad material 1 may have a configuration in which a duralumin material and another aluminum material are laminated on the aluminum material 3 in a forward field and the duralumin is sandwiched between the aluminum materials.

(Second Embodiment)
A method for manufacturing a composite product of a clad material and a synthetic resin part in the second embodiment of the present invention will be described with reference to FIG.

First, the clad material 1 is pretreated in step S201. This process is the same as in the first embodiment. Next, in step S202, a partial mask is formed on the surface of the clad material 1 by printing. As shown in FIGS. 15 and 16, the partial mask 41 is formed on the surface of the aluminum material 3 of the clad material 1 at a portion where a resin component is later joined. For the partial mask 41, for example, UV (ultraviolet) curable ink can be used. In this case, after the ink is applied to the surface of the aluminum material 3 by printing, UV light is irradiated. Thereby, the ink is cured and the partial mask 41 is formed. Note that the partial mask 41 may be formed before the pretreatment.

Next, in step S203, the clad material 1 is press-molded as in the first embodiment. Further, in step S204, masking by electrodeposition coating is performed. Electrodeposition coating is performed on the entire surface of the clad material 1, whereby a uniform coating film 4 is formed. This step is performed in the same manner as in the first embodiment. As shown in FIG. 17, since the coating film 4 is not formed on the partial mask 41, the partial mask 41 is exposed in this region.

Thereafter, in step S205, the partial mask 41 is peeled off using an ink remover. The ink remover uses a solvent that dissolves the partial mask 41 but does not dissolve the coating film 4, for example, a non-chlorine solvent.

When only the partial mask 41 is peeled off from the surface of the aluminum material 1, the aluminum material 1 in the region where the partial mask 41 was formed is exposed. As a result, an opening 4A similar to FIG. 4 is formed.

In step S206, the partial mask 41 is peeled off to form the anodized film 5 as a bonding film in the region where the aluminum material is exposed. Further, in step S207, the synthetic resin component 7 is bonded onto the anodized film 5. These steps are performed in the same manner as in the first embodiment.

Thereby, as shown in FIG. 18, a composite product 8 is obtained in which the synthetic resin component 7 is bonded onto a partial region of the aluminum material 3 of the clad material 1.

As described above, in this embodiment, since the coating film 4 is partially removed using the partial mask 41, it is possible to define a flow area where the synthetic resin component 7 is joined only by chemical solution processing. it can.

(Third embodiment)
In this embodiment, in step S106 or step S207, the clad material 1 and the synthetic resin component 7 are manufactured separately, and both members are joined by a thermocompression bonding method to manufacture the composite product 8.

FIG. 19 shows an example of a manufacturing apparatus for manufacturing a composite product by a thermocompression bonding method. The manufacturing apparatus 51 includes an electromagnetic induction heating device 52 and a press head 53 that can be raised and lowered. The press head 53 is connected to a pressurizing cylinder (not shown).

In the electromagnetic induction heating device 52, a planar heating coil 56 is embedded in the bottom 55 </ b> A of the holder 55 that accommodates the clad material 1. The coil 56 is connected to a high frequency oscillator 57 provided outside.

When joining the synthetic resin component 7, the clad material 1 is first accommodated in the holder 55. The clad material 1 is disposed with the surface on which the anodized film 5 is formed facing upward. Further, the synthetic resin component 7 is placed on the joining position, that is, on the anodized film 5.

Next, the press head 53 is lowered, the synthetic resin part 7 is pressurized from above, and is pressed against the anodized film 5. In this state, the high frequency oscillator 57 is operated to energize the coil 56, and the clad material 1 is heated by induction heating.

Thereby, the synthetic resin part 7 is heated through the clad material 1, and the portion of the synthetic resin part 7 that is pressure-bonded to the anodized film 5 is melted and enters the hole 6 of the anodized film 5. Thereafter, when the clad material 1 and the synthetic resin component 7 are cooled and the press head 53 is raised, a composite product 8 in which the synthetic resin component 7 is bonded to the clad material 1 through the anodized film 5 is obtained.

Here, in this manufacturing apparatus 51, if the high-frequency output of the high-frequency oscillator 57 is set to, for example, 500 W to 50 kW and the frequency 50 kHz to 3 MHz, the composite product 8 having sufficient bonding strength can be obtained by energization for about 10 to 12 seconds.

The features of each embodiment are added below.

In this method of manufacturing a composite product of a clad material and a synthetic resin part, an anodized film is formed only on a part of the clad material on the aluminum material side. Since the portion made of a material other than the aluminum material is protected by the film, the portion made of the material other than the aluminum material is not damaged by the chemical solution or current when forming the anodized film.

Further, only the film in the region irradiated with the CO ₂ laser is removed. Since the coating is more accurately removed by reducing the pitch of the laser light irradiation, an anodic oxide coating can be formed reliably.

Moreover, in this method of manufacturing a composite product of the clad material and the synthetic resin part, it becomes possible to remove a part of the film only by chemical treatment. Since only the partial mask is dissolved, other regions covered with the film can be reliably protected.

When the pore diameter of the anodized film is increased, the strength when the synthetic resin parts are joined increases.

When a synthetic resin part is molded by injection molding, the synthetic resin part can be joined by the molten synthetic resin entering the holes of the anodized film. The synthetic resin part partially melts at the contact surface between the anodized film and the synthetic resin part and enters into the holes of the anodized film. Thereby, a synthetic resin component is joined to a clad material. While having the texture and strength of a stainless steel material, the weight can be reduced by using an aluminum material.

In the composite product of this clad material and synthetic resin part, the texture and strength of the stainless steel material can be obtained by using the stainless steel material on the outer surface. It is possible to reduce the weight by using an aluminum material on the inner surface, and to join a synthetic resin component using the aluminum material. For example, the synthetic resin component can be engaged with another component or used as a spacer.

This composite product of the clad material and the synthetic resin part can be attached detachably by engaging the synthetic resin part with another member.

The composite product according to each embodiment includes components such as electrical devices such as personal computers and mobile phones, electronic device parts, building materials, indoor and outdoor equipment products, ships, aircraft, railway vehicles, automobiles, and the like. , It can be applied to composite products of clad materials and synthetic resin parts having various sizes and shapes, such as external device products and decorative products such as license plates.

The present invention is interpreted without being limited to the examples and conditions given in the embodiment. Various changes and modifications can be made to the present invention without departing from the spirit and scope thereof.

DESCRIPTION OF SYMBOLS 1 Cladding material 2 Stainless steel material 3 Aluminum material 4 Paint film 5 Anodized film 6 Hole 7, 33, 35 Synthetic resin part 8 Composite product 30 Cover 31, 32 Peripheral part

Claims (10)

Forming a film by electrodeposition coating on the entire surface of the clad material provided with an aluminum material on at least one surface;
Removing a part of the film formed on the surface of the aluminum material;
Forming an anodized film on the surface of the aluminum material exposed by removing the film;
Forming a composite product by joining the clad material and the synthetic resin component by allowing a portion of the synthetic resin component to enter a large number of holes in the anodized film;
Of a composite product of a clad material and a synthetic resin part including The method for producing a composite product of a clad material and a synthetic resin part according to claim 1, wherein the step of removing a part of the coating is a step of removing the coating by irradiation with a CO ₂ laser. While irradiating the laser beam in a line in the first direction and sending the laser beam at a pitch of 0.01 mm to 0.2 mm in a second direction substantially orthogonal to the first direction, The manufacturing method of the composite material of the clad material and synthetic resin parts of Claim 2 to remove. After forming a partial mask on a part of the surface of the aluminum material, forming the film on the entire surface of the clad material including on the partial mask in the step of forming a film by the electrodeposition coating, The method of manufacturing a composite product of a clad material and a synthetic resin part according to claim 1, wherein in the step of removing the portion, a part of the coating is removed by dissolving the partial mask. The method for producing a composite product of a clad material and a synthetic resin part according to any one of claims 1 to 4, wherein the anodized film has a large number of holes having a diameter of 40 nm to 100 nm. The method for producing a composite product of a clad material and a synthetic resin part according to claim 1 or 5, wherein the synthetic resin part is formed by injection molding. The method for producing a composite product of a clad material and a synthetic resin part according to claim 1 or 5, wherein the synthetic resin part is pressed and joined to the anodized film while heating. The method for manufacturing a composite product of a clad material and a synthetic resin part according to any one of claims 1 to 7, wherein the clad material is a clad material obtained by superposing a stainless steel material on the aluminum material. A clad material in which an aluminum material is superimposed on a stainless steel material;
An anodized film formed on a part of the aluminum material;
A synthetic resin component joined to the clad material by partially entering the holes of the anodized film;
A composite product of clad material and synthetic resin parts. The clad material and the synthetic resin component according to claim 9, wherein the anodized film is formed on a peripheral portion of the clad material, and the resin member is a claw used for engaging the clad material with another component. Composite product.

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