Taisei Plas Co., Ltd.

Naoki Andoh

Masanori Naritomi

Naoki Yamano

Yoshihiro Yamaguchi

Makoto Iwahashi

Michiyuki Nakase

An aluminum alloy material is prepared that has surface configuration of threefold irregularities such that rough surface having surface roughness of 10 to 100 μm period is observed with an electron microscope in a magnification of 1000 times, surface having fine irregularities of 1 to 5 μm period based on crystal grain boundary is observed with an electron microscope in a magnification of 10000 times and surface having ultrafine irregularities of 30 to 100 nm period is confirmed with an electron microscope in a magnification of 100000 times. Aluminum alloy material is integrally joined with a resin composition consisting of a total resin part containing polyphenylene sulfide resin by 70 mass % or more of the resin part, modified polyolefin resin by 30 mass % or less of the resin part and a resin of third component having ability for promoting compatibility of polyphenylene sulfide resin and modified polyolefin resin.

Method for manufacturing a composite of aluminum alloy

It is an object of the present invention to securely and integrally join a metal and a resin, more particularly, a shaped titanium alloy substrate and a resin composition. A titanium alloy substrate is used that has undergone surface roughening by chemical etching or the like so as to have a ultrafine textured face in which bent, ridge-like protrusions having a width and height of from ten to a few hundred nanometers and a length of from a few to a few hundred microns rise up on the surface at a spacing period of from ten to a few hundred nanometers. A titanium alloy piecewith its surface treated is inserted into the cavity of a metallic mold for injection moldingand a specific resin compositionis injected to obtain an integrated composite. The main resin component of the resin compositionthat is used can be a polyphenylene sulfide resin (PPS) or a polybutylene terephthalate resin (PBT). High injection joining strength is obtained if the resin composition contains, as an auxiliary component, a polyethylene terephthalate resin and/or polyolefin resin in the case of PBT and a polyolefin resin in the case of PPS.

Method for preparing a composite of metal and resin

A magnesium alloy part is inserted into a mold, a resin composition is injected and joined to the part, and a composite is obtained. A part having, formed thereon, a surface layer of a metal oxide, a metal carbonate, or a metal phosphate in use of a usual conversion treatment or a modification method thereof can be used for the magnesium alloy plate. The surface that has a larger amount of crystal-like objects of a nanolevel on the surface layer composed of the metal oxide, metal carbonate, or metal phosphate has a higher level of hardness, microscopic roughness, and good injection joining force, and these parameters can be controlled by a conversion treatment method. A resin composition, containing PBT or PPS as the main component, is used as the resin composition part.

Composite of metal and resin and method for manufacturing same

There is provided a technique to strongly integrate a galvanized steel sheet and a resin molded article. A hot-dip galvanized steel sheet is immersed in an aqueous solution for aluminum degreasing to form a specific roughness on the surface. The surface is covered with convex protrusions having a diameter of about 100 nm, and a chromate treatment layer appears in the surface. A resin composition comprising 70 to 97 wt % of polyphenylene sulfide and 3 to 30 wt % of a polyolefin resin is injected onto the surface. The resin composition penetrates into ultra-fine irregularities and is cured in that state, and thereby a composite in which the galvanized steel sheet and the resin molded article are strongly integrated can be obtained. The shear rupture strength of the composite is extremely high.

Method for manufacturing a bonded body of galvanized steel sheet and adherend

It is an object to manufacture a composite of a metal part and a resin composition part, which is improved so as to securely join and integrate stainless steel and a resin. A stainless steel part whose surface has been suitably roughened by chemical etching or the like can be used. An integrated product is obtained by inserting a stainless steel piecewith its surface treated into a cavity formed by a movable-side mold plateand a fixed-side mold plateof a metallic mold for injection moldingand injecting a specific resin. PBT, PPS or an aromatic polyamide resin can be used as the main resin component of a resin composition 4 that is used. High injection joining strength is obtained if the resin composition contains, as an auxiliary component, PET and/or a polyolefin resin in the case of PBT, a polyolefin resin in the case of PPS and an aliphatic polyamide resin in the case of an aromatic polyamide resin.

Composite of metal and resin and method for manufacturing the same

A metal-resin composite having high gas sealing properties is provided. An aluminum alloy structure having a shape surrounding the copperis firstly formed, and the attached aluminum alloy is made closely contact with the copper electrodeand further made engaged into the copper electrodeby pressing or forging. It is then machined into a predetermined shape so as to prepare the copper alloyattached with an aluminum alloy part 61a. Subsequently, the surface treatment of the NMT or NMT 2 is given to three members of an aluminum electrode, the copper electrodeattached with the aluminum alloy partand an aluminum alloy lid. These three members are inserted into an injection mold, and a thermoplastic resin compositionof PPS resin is injected. The lithium-ion battery lidhaving a structure as shown in FIG.is thus obtained.

Metal-resin complex and process for production thereof

A method for preparing a copper alloy given a certain special surface shape yields tremendous bonding strength through compatibility with an epoxy resin adhesive. With a composite part in which this technology is utilized to integrate a copper alloy member as a cover material with a CFRP, it is possible to take advantage of the characteristics of both the copper alloy and the FRP due to the tremendous bonding strength. In a step in which an FRP prepreg is put into a mold and heated and cured, usually the mold is first coated with a release agent to facilitate release from the mold, but with high-technology CFRP, bleeding of the release agent often diminishes the properties. A copper alloy sheetis used as a cover material, and a CFRPis cured.

Copper alloy composite and method for manufacturing same

The object of the present invention is to strongly join an aluminum alloy part with an FRP prepreg. An object obtained by subjecting an aluminum alloy to a suitable liquid treatment so as to form a surface having large, micron-order irregularities and also fine irregularities with a period of several tens of nanometers, eliminating the presence of sodium ions from the surface and additionally forming a surface film of aluminum oxide, which is thicker than a natural oxide layer, has been found to have a powerful adhesive strength with epoxy-based adhesives. By simultaneously curing an FRP prepreg which uses the same epoxy-based adhesive in the matrix, an integral composite or structure in which FRP and aluminum alloy have been united at a joining strength of unprecedented magnitude is produced.

Aluminum alloy composite and method for joining thereof

A composite of a metal part and a resin composition part that is improved so that the metal and resin are integrally joined to have strong bonding properties, and a method for manufacturing the composite. A magnesium alloy part is inserted into a mold, a resin composition is injected and joined to the part, and a composite is obtained. A part having, formed thereon, a surface layer of a metal oxide, a metal carbonate, or a metal phosphate in use of a usual conversion treatment or a modification method thereof can be used for the magnesium alloy plate. The surface that has a larger amount of crystal-like objects of a nanolevel on the surface layer composed of the metal oxide, metal carbonate, or metal phosphate has a higher level of hardness, microscopic roughness, and good injection joining force, and these parameters can be controlled by a conversion treatment method. A resin composition, containing PBT or PPS as the main component, is used as the resin composition part.

In the composite, an aluminum-plated steel sheet and a resin are securely and integrally joined together. Through chemical etching, the aluminum-plated steel sheet is caused to have a surface configuration, in which three-dimensional protrusions having shapes with a minor diameter of at least 0.3 &#x3bc;m and a major diameter of at least 3 &#x3bc;m are scattered over a plain part and a portion covered with shallow fine recesses with a diameter of 20 to 50 nm in a state of being distributed adjacent to each other on the plain part accounts for 30 to 50% of the surface area of the plain part. The surface of the three-dimensional protrusions is mainly ceramic containing silicon and the plain part is mainly ceramic containing aluminum. The resin is joined through injection molding with the aluminum-plated steel sheet having been inserted into a metallic mold.

Composite of steel and resin and method for manufacturing same

A composite of a magnesium part or a magnesium alloy part and a resin composition, improved to have high corrosion resistance, is manufactured by: a step of shaping a magnesium alloy partfrom a casting or an intermediate material; a step of immersing and chemically etching the shaped part in an acidic aqueous solution; a step of immersing the chemically etched shaped part in an aqueous solution containing potassium permanganate and forming on the surface thereof a thin layer having manganese oxide as a component; a step of inserting the part, on which the thin layer has been formed, into a metallic mold for injection molding and injecting into the mold a resin composition selected out of a resin composition whose main component is polyphenylene sulfide, a resin composition whose main component is a polybutylene terephthalate resin and a resin composition whose main component is an aromatic polyamide resin and then integrally affixing the magnesium alloy partand the resin composition; and a step of subjecting the integrally affixed compositeto a chemical conversion treatment by immersing it again in a magnesium alloy chemical conversion treatment solution.

Method for manufacturing composite with high corrosion resistance

An object of the present invention is to obtain a composite in which a copper or copper alloy is securely integrated with and joined to PBT or PPS. A copper product that has been suitably roughened by chemical etching and also blackened can be used favorably. A surface-treated copper pieceis inserted into a cavity formed by a movable molding plateand a stationary molding plateof an injection molding mold, and a specific resin is injected to obtain an integrated product. PBT or PPS can be used as the resin component of a resin compositionthat is used here. High injection joining strength is obtained if the resin composition contains, as an auxiliary component, PET and/or a polyolefin resin in the case of PBT, and a polyolefin resin in the case of PPS.

Metal and resin composite and method for manufacturing same

A composite of a metal and a resin, in which a shaped metal and a shaped thermoplastic resin are integrally joined by injection molding, and in which the perpendicular precision of the thermoplastic shaped body with respect to the shaped metal is improved, as well as a method for manufacturing the composite. A compositeof a metal and a resin is composed of a shaped metaland a shaped thermoplastic resin that is integrally joined to this shaped metalby injection molding. The shaped thermoplastic resin comprises a seatand a bossthat protrudes from the seat. A runneris provided which communicates with the seatvia two sprues and through which a molten thermoplastic resin that has been injected through an injection gateflows into the bossand the thermoplastic resin injected through the injection gateflows through the spruesto opposite locations of the bosssubstantially uniformly, thereby filling the locations. As a result, the bosscan be joined perpendicularly to the shaped metalby injection joining.

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Tokyo, Japan

Naoki Andoh