Method for manufacturing metal-resin composites

Abstract

To provide a metal-resin composite and a member thereof that can be used in a variety of applications while ensuring airtightness or liquid-tightness.SOLUTION: A metal-resin composite member 2, 21 of the present invention is formed by tightly bonding a long metal member 3 to a molded solid 5 of a thermoplastic resin having an annular protrusion 6, with the metal member 3 protruding from one or both ends of the molded solid 5, and a metal-resin composite 1 according to the present invention is formed by covering the metal-resin composite member 2, 21 with a housing 7 made of the same type of thermoplastic resin, the annular protrusion 6 being melted and tightly bonded to the molded solid 5, to form a space 8, and the metal member 3 being placed in this space 8.SELECTED DRAWING: Figure 1

Description

Technical Field

[0002]

[0001] The present invention is applicable to various applications Method for manufacturing metal-resin composites and relates to

Background Art

[0002] In a metal resin composite in which a long metal member is coated with a thermoplastic resin to ensure airtightness or liquid tightness, it is necessary to make it difficult for moisture to penetrate from the end face of the metal member. For example, as shown in Patent Document 1, in the housing of portable electronic devices such as mobile phones, notebook computers, electronic notebooks, video cameras, etc., airtightness and liquid tightness for preventing moisture and rainwater from entering the inside of the electronic device are required. In vehicles such as automobiles, a large number of electronic devices such as electronic control units (ECUs) for engine control systems, steering systems, drive systems, air conditioning systems, etc., and various sensors and actuators are mounted. Regarding the housings of these in-vehicle electronic devices, a metal composite joint has been proposed, taking up the issue that airtightness and liquid tightness are similarly required.

[0003] In the metal composite joint proposed in this Patent Document 1, in the range of the joint interface where the metal member contacts a different member such as PPS resin, 10 to 100 airtightness retaining grooves with a depth of 5 μm to 15 μm and a pitch of 100 μm are formed, and the different member is injection molded, and the molten different member enters the airtightness retaining grooves, and the metal member and the different member are joined without a gap.

[0004] However, in Patent Document 1, even for a member for a metal composite in which a metal member is closely joined to a different member such as PPS resin, the housing covering the member for the metal composite is not described, and ensuring airtightness or liquid tightness between the housing and the member for the metal composite is not described either.

[0005]

Prior Art Documents

Patent Documents

[0006] [Patent Document 1] Japanese Patent Publication No. 2011-240685, Japanese Patent Publication No. 2011-152001, Japanese Patent Publication No. 2011-152001 [Overview of the project] [Problems that the invention aims to solve]

[0007] This invention The method for manufacturing metal-resin composites is: Ensure airtightness or liquid tightness. The connector has terminals The objective is to provide a metal-resin composite. [Means for solving the problem]

[0008] The method for manufacturing a metal-resin composite according to claim 1 of the present invention comprises: a metal member roughening step in which roughened portions are formed on the surface of a plurality of elongated metal members that will serve as terminals of a connector by laser irradiation; a metal member and molded solid joining step in which a molded solid having an annular projection is formed by placing the roughened portions of each metal member into an injection molding die with the plurality of elongated metal members produced in the metal member roughening step spaced apart so that they are not in contact with each other, and injecting a thermoplastic resin heated and melted into the injection molding die to form a metal-resin composite member in which the metal member and molded solid are tightly joined to the roughened portions of the metal member; and the metal part The metal-resin composite member is manufactured by a process of joining a material and a molded solid, wherein a metal-resin composite member having an annular protrusion formed on the outer circumference of the molded solid is subjected to a process of laser irradiation to form fine irregularities on the surface of the annular protrusion formed on the outer circumference of the molded solid, and the metal-resin composite member having an annular protrusion with fine irregularities formed thereon is placed in an injection molding die, and a thermoplastic resin of the same type as the molded solid is heated and melted and injected into the injection molding die to form a housing that is tightly bonded to the molten annular protrusion of the molded solid and covers the surface of the metal-resin composite member, thereby forming a space and arranging the metal member in the space, thereby manufacturing a metal-resin composite. [Effects of the Invention]

[0009] The present invention provides a method for manufacturing a metal-resin composite, comprising: a metal member roughening step, in which roughened areas are formed on the surface of a plurality of elongated metal members that will serve as terminals for a connector by laser irradiation; a metal member and molded solid joining step, in which the roughened areas of the plurality of elongated metal members manufactured in the metal member roughening step are placed in an injection molding die with the metal members spaced apart so as not to be in contact with each other, and a thermoplastic resin is heated, melted, and injected into the injection molding die to form a molded solid having an annular projection, thereby manufacturing a metal-resin composite member in which a molded solid is tightly bonded to the roughened areas of the metal members; and a metal resin manufactured in the metal member and molded solid joining step. The process involves forming an annular projection on the outer circumference of the molded solid of the composite material by laser irradiation to create fine irregularities on its surface. The metal-resin composite material having an annular projection with fine irregularities formed on its surface is then placed in an injection molding die. A thermoplastic resin of the same type as the molded solid is heated and melted and injected into the injection molding die to form the housing, which is tightly bonded to the molten annular projection of the molded solid and covers the surface of the metal-resin composite material. A space is formed in this space, and the metal component is placed in this space. This process of bonding the molded solid and the housing ensures that the metal-resin composite material has airtight or liquid-tight connector terminals. [Brief explanation of the drawing]

[0010] [Figure 1] This shows Embodiment 1 of the metal-resin composite of the present invention, where (a) is a plan view, (b) is a right side view, and (c) is a cross-sectional view AA. [Figure 2] This shows two embodiments of the metal-resin composite of the present invention, where (a) is a plan view, (b) is a right side view, and (c) is a cross-sectional view of BB. [Figure 3] This shows Embodiment 1 of the metal-resin composite member of the present invention, where (a) is a plan view, (b) is a right side view, (c) is a CC cross-sectional view, and (d) is a DD cross-sectional view. [Figure 4] This shows an embodiment 2 of the metal-resin composite member of the present invention, where (a) is a plan view and (b) is a right side view. [Figure 5] This shows three embodiments of the metal-resin composite member of the present invention, where (a) is a plan view, (b) is a right side view, and (c) is an EE cross-sectional view. [Figure 6] This document describes the manufacturing process for the metal-resin composite component and the metal-resin composite of the present invention. [Modes for carrying out the invention]

[0011] (Regarding metal-resin composites using metal-resin composite components) The metal-resin composites 1 and 11 utilize metal-resin composite members 2, 21, and 22, in which a long metal member 3 is tightly bonded to a molded solid 5 made of thermoplastic resin at a roughened surface 4. As shown in Figure 1(c) or Figure 2(c), a housing 7 tightly bonded to the molded solid 5 forms a space 8 in which a small space 81 containing the metal member 3 and a larger space 82 communicate in the longitudinal direction (left-right direction in the figure) of the metal member 3, and the metal member 3 is placed in this space 8. In this case, the small space 81 in metal-resin composite member 2 and 21 is formed by the housing 7 being joined annularly to the end face of the molded solid 5, as shown in Figure 1(c), and the small space 81 in metal-resin composite member 22 is formed by the housing 7 being joined annularly to the end face of the housing joined to the metal member 3, as shown in Figure 2(c). Furthermore, the molded solid 5 of these metal-resin composite members 2, 21, and 22 has a meltable annular projection 6, which is used in the formation of the space 8 and melts to form a molten portion 6A, contributing to the close bonding of the housing 7 and the molded solid 5. In the metal member 3, as will be described later, the surface is roughened, and this roughening contributes to the close bonding of the metal member 3 and the molded solid 5. In this way, airtightness or liquid tightness is ensured in both the close bonding of the metal member 3 and the molded solid 5 and the close bonding of the molded solid 5 of the metal-resin composite members 2, 21, and 22 to the housing 7 so as to cover the metal-resin composite members 2, 21, and 22. By using the elongated metal member 3 as the terminal of a connector used for electrical connection, a waterproof connector with a waterproof function can be provided. Furthermore, if thermoplastic resins such as PPS resin are used as the material for the molded solid 5 of the metal-resin composite member 2, 21 and the housing 7 of the metal-resin composite 1, a waterproof connector with a more desirable waterproof function in terms of heat resistance and chemical resistance can be provided.

[0012] (Regarding components for metal-resin composites) The metal-resin composite members 2, 21, and 22 are formed by a long metal member 3 being tightly bonded to a molded solid 5 of thermoplastic resin, with the metal member 3 protruding from one or both ends of the molded solid 5. While the long metal member 3 is exemplified as being linear, it may also be curved. Its surface is roughened, as shown in Figure 3(d) or Figure 5(c), and the roughened portion 4 is tightly bonded to the molded solid 5 obtained by insert molding of the thermoplastic resin, ensuring airtightness or liquid tightness. A meltable annular projection 6, which provides the molten portion 6A in the metal-resin composites 1 and 11, extends from the outer circumference of the molded solid 5, which is made of a thermoplastic resin such as PPS resin. This annular projection 6 protrudes from the surface of the molded solid 5 in a direction intersecting the metal member 3, but it may also protrude in the direction of the metal member 3. Furthermore, while it is formed at the right end of the molded solid 5 in Figure 3(a), it may also be formed at both the left and right ends, as shown in Figure 5(a). In the metal member 3, the material can be copper (including copper alloys), and although its cross-section is shown as rectangular, it may also be round. Furthermore, the figure shows two metal members 3 formed symmetrically on the molded solid 5, but the number of metal members 3 can be one or more. In the molded solid 5 where two metal members 3 are formed symmetrically, the 9 indicated in Figure 3(c) shows a gate mark. By injecting thermoplastic resin into an injection mold with the two metal members 3 mounted symmetrically, the thermoplastic resin is uniformly filled and molded. In this way, the metal-resin composite members 2, 21, and 22 ensure airtightness or liquid tightness for use in metal-resin composites, and can be used for multiple long metal members and for metal-resin composites of various shapes depending on the application.

[0013] (Method 1 of metal-resin composite) Embodiment 1 of the metal-resin composite using Embodiments 1 and 2 of the metal-resin composite member will be described below with reference to Figures 1(a), (b), and (c).

[0014] In FIGS. 1(a), (b) and (c), the metal resin composite 1 is formed by using members 2 and 21 for the metal resin composite, in which a long metal member 3 is joined to a molded solid 5 of a thermoplastic resin, and the housing 7 joined to the molded solid 5 covers the members 2 and 21 for the metal resin composite to form a space 8. In the joining of the metal member 3 and the molded solid 5, airtightness or liquid tightness is ensured, and in the joining of the molded solid 5 and the housing 7, a melted portion 6A indicating that the annular projecting piece 6 of the molded solid 5 is melted contributes to the close joining to ensure airtightness or liquid tightness. In this case, the thermoplastic resin of the molded solid 5 and the housing 7 can be exemplified by PPS resin, and may contain inorganic fibers such as glass fibers.

[0015] By the joining of the molded solid 5 and the housing 7, as shown in FIG. 1(c), a space 8 is formed in which the long metal members 3 protruding from both ends of the molded solid 5 of the members 2 and 21 for the metal resin composite are arranged, and the metal members 3 are arranged in this space 8. In this case, the space 8 may be formed only at one end, for example, the right end, so that the long metal members 3 are arranged only at one end, for example, the right end of the molded solid 5 of the members 2 and 21 for the metal resin composite.

[0016] (Embodiment 2 of the metal resin composite) The embodiment 2 of the metal resin composite using the embodiment 3 of the member for the metal resin composite will be described below based on FIGS. 2(a), (b) and (c).

[0017] In FIGS. 2(a), (b) and (c), the metal resin composite 11 is composed of the same materials as in the first embodiment of the metal resin composite. A housing 7 joined to the molded solid body 5 covers a member 22 for the metal resin composite to form a space 8, and a metal member 3 is disposed in this space 8. In forming this space 8, a long metal member 3 is covered with a member 22 for the metal resin composite formed by joining the molded solid body 5 of the thermoplastic resin by a housing 7 joined to the molded solid body 5 and the metal member 3. The close joining between the housing 7 and the molded solid body 5 is due to the contribution of the close joining of a molten part 6A indicating that an annular projection 6 similar to that in the first embodiment of the metal resin composite has melted. In addition to this, the close joining between the housing 7 and the metal member 3 Roughened part 4 contributes to the close joining between them, and due to the close joining of both, higher airtightness or liquid tightness can be ensured compared to the close joining between the molded solid body 5 and the housing 7 in the first embodiment of the metal resin composite.

[0018] (First Embodiment of Member for Metal Resin Composite) Next, the first embodiment of the member for the metal resin composite used in the first embodiment of the metal resin composite will be described below based on FIGS. 3(a), (b), (c) and (d).

[0019] In Figures 3(a), (b), (c), and (d), each of the two elongated metal members 3 has a roughened surface area 4 extending over a length L by laser irradiation. These two metal members 3 are arranged symmetrically, and thermoplastic resin is injected into an injection mold as shown in the gate mark 9 in Figure 3(c). The thermoplastic resin is uniformly filled and insert molded, and the elongated metal members 3 are tightly bonded to the molded solid 5 of the thermoplastic resin at the roughened surface area 4, resulting in a metal-resin composite member 2 having metal members 3 protruding from both ends of the molded solid 5. In the metal-resin composite member 2 obtained in this way, a molten annular projection 6 is molded on the surface of the molded solid 5 so as to extend in a direction intersecting with the metal member 3. A housing 7 is formed by insert molding of the same type of thermoplastic resin as the molded solid 5, and at that time, the annular projection 6 is molten and bonded in the molten part 6A, contributing to the tight bonding of the housing 7 and the molded solid 5, making it useful for a metal-resin composite 1.

[0020] The illustration shows that this annular projection 6 is made of the material of the molded solid 5 and extends outwards from the outer circumference of the molded solid 5, protruding in a direction intersecting with the metal member 3. It is sufficient that it protrudes in the direction of the metal member 3 from the end face of the molded solid 5 and extends outwards from the outer circumference of the molded solid 5, and is melted so as to be used in the metal-resin composite 1 during the integral molding of the molded solid 5 and the housing 7.

[0021] (Embodiment 2 of a component for metal-resin composites) Embodiment 2 of the metal-resin composite member of the present invention is shown in Figures 4(a) and (b), and is an invention in which the annular projection 6 is surface-treated in the metal-resin composite member 2 described in Embodiment 1 of the metal-resin composite member, and will be described below.

[0022] In Figures 4(a) and (b), fine irregularities 61 are formed on the surface of a meltable annular projection 6 extending from the outer circumference of the molded solid 5, forming a metal-resin composite member 21. As shown in the partially enlarged view, these fine irregularities 61 are formed on the surface by, for example, creating multiple discontinuous depressions of about 100 μm in the region of the annular projection 6 by laser irradiation. These fine irregularities 61 make the annular projection 6 easier to melt, allowing it to be used in a metal-resin composite 1 with improved adhesion when joining the molded solid 5 and the housing 7.

[0023] (Embodiment 3 of a component for metal-resin composites) Embodiment 3 of the metal-resin composite member of the present invention is shown in Figures 5(a), (b), and (c), and will be described below.

[0024] In Figures 5(a), (b), and (c), the molded solid 5 is made of the same material as in Embodiment 1 of the metal-resin composite member, and the surfaces of both elongated metal members 3 are roughened by laser irradiation. However, unlike Embodiment 1 of the metal-resin composite member, the length L of the roughened portion 4 is longer than the length M of the molded solid 5 that is to be tightly bonded. In this tightly bonded molded solid 5, meltable annular projections 6 are formed at both ends (left and right ends in the figure) so as to extend in a direction intersecting with the metal members 3, forming the metal-resin composite member 22. In this metal-resin composite member 22 as well, when the housing 7 is molded by insert molding of the same type of thermoplastic resin as the molded solid 5, the annular projections 6 are melt-bonded in the molten portion 6A, similar to Embodiment 1 of the metal-resin composite member, and contribute to the tight bonding of the housing 7 and the molded solid 5, making it useful for the metal-resin composite 11. Furthermore, fine irregularities 61 may be formed on the surface of the annular projections 6, similar to the annular projections 6 in Embodiment 2 of the metal-resin composite member.

[0025] (Regarding the manufacture of metal-resin composite components and metal-resin composites) Figure 6 shows the manufacturing process for a metal-resin composite component, including the surface roughening process 101 for the metal component and the joining process 102 between the metal component and the molded solid, as well as the manufacturing process for the metal-resin composite, including the joining process 103 between the molded solid and the housing.

[0026] In the manufacturing process for metal-resin composite components shown in Figure 6, the metal component roughening step 101 is a process in which a portion of the elongated metal component 3 is roughened by laser irradiation to form a portion 4. An example of the laser irradiation roughening method is the formation of an anchor portion on the metal surface by laser irradiation as described in Patent No. 6879615 held by the present applicant. The joining process 102 between the metal member and the molded solid is a work process for obtaining a metal-resin composite member 2, and consists of the following steps: a work process in which multiple long metal members 3 manufactured in the metal member roughening process 101 are spaced apart so that they are not in contact with each other and are placed in an open injection molding die; a work process in which the injection molding die is closed and heated and molten thermoplastic resin is injected into the injection molding die to form annular protrusions 6 on the outer circumference of the molded solid 5 and the thermoplastic resin enters the roughened portion 4 of the metal member 3 to insert mold the metal member 3 and tightly join the metal member 3 and the molded solid 5; a work process in which the injection molding die is cooled; and a work process in which the injection molding die is opened and the metal-resin composite member 2 is removed. Furthermore, by insert molding a portion of the elongated metal member 3 that has been roughened by laser irradiation, making the length of that portion 4 longer than the length of the portion 4 that tightly bonds the metal member 3 and the molded solid 5, a metal-resin composite member 22 can be obtained.

[0027] Next, in the manufacturing process of the metal-resin composite shown in Figure 6, the joining process 103 between the molded solid and the housing is a work process to obtain metal-resin composites 1 and 11 using metal-resin composite members 2, 21 and 22, and consists of a work process of mounting the molded solid of the metal-resin composite member into an open injection mold, a work process of obtaining a housing with a space formed therein, a work process of cooling the injection mold, and a work process of opening the injection mold and removing the metal-resin composites 1 and 11.

[0028] Therefore, in the joining process 103 between the molded solid and the housing, the work process to obtain a housing with a space formed therein refers to integral molding of the housing and the molded solid or integral molding of the housing, the molded solid and the metal member, and will be explained below.

[0029] In the process of mounting the molded solids for the metal-resin composite into an open injection mold, the metal-resin composite members 2, 21, and 22 are mounted into the injection mold. Next, in the process of obtaining a housing with a space formed, the injection mold is closed and a thermoplastic resin of the same type as the molded solid 5 is heated and melted and injected into the injection mold, thereby forming a housing 7. In the molding of this housing 7, the annular protrusions 6 of the molded solid 5 melt, and a space 8 consisting of a small space 81 and a large space 82 is formed in the housing 7 containing the molten portion 6A, with the metal member 3 positioned in this space 8. Next, after a process of cooling the injection mold, the metal-resin composites 1 and 11 are obtained in the process of opening the injection mold and removing the metal-resin composites 1 and 11. In this case, in the metal-resin composite 1, the metal-resin composite members 2 and 21 are covered by a housing 7 that is tightly bonded to the molded solid 5, forming a space 8 in which the metal member 3 is placed. In the metal-resin composite 11, the metal-resin composite member 22 is covered by a housing 7 that is tightly bonded to the molded solid 5 and also tightly bonded to the metal member 3, forming a space 8 in which the metal member 3 is placed.

[0030] In this way, the elongated metal members 3 in the aforementioned metal-resin composite members 2, 21, and 22 are tightly bonded to a molded solid 5 of thermoplastic resin having annular projections 6, resulting in metal-resin composite members 2, 21, and 22 with the metal members 3 protruding from one or both ends of the molded solid 5. The metal-resin composite members 2, 21, and 22 are covered by a housing 7 in which the annular projections 6 are melted and tightly bonded to the molded solid 5, forming a space 8, and the metal members 3 are placed in this space 8 to obtain metal-resin composites 1 and 11. Thus, airtightness or liquid tightness is ensured in both the metal-resin composite members 2, 21 and the metal-resin composites 1 and 11.

[0031] (Regarding the applications of metal composites) Multiple long metal components can be combined into square or round shapes and used as terminals for various connectors used in electrical connections to meet airtight or liquid-tight requirements. [Explanation of Symbols]

[0032] 1 Metal resin composite 11 Metal-resin composite 2. Components for metal-resin composites 21 Components for metal-resin composites 22 Components for metal-resin composites 3 Metal components 4. Roughened areas 5 Molded solid 6. Annular projections 6A Molten section 61 Fine irregularities 7 Housing 8 Space section

Claims

[Claim 1] A metal member roughening step to form roughened areas on the surface of a plurality of elongated metal members that will serve as terminals of a connector by laser irradiation; a metal member and molded solid joining step to manufacture a metal-resin composite member, wherein the plurality of elongated metal members manufactured in the metal member roughening step are spaced apart so as not to be in contact with each other, the roughened areas of each metal member are placed in an injection molding die, and a thermoplastic resin is heated, melted, and injected into the injection molding die to form a molded solid having an annular projection, which is then tightly bonded to the roughened areas of the metal members; and the metal member and molded solid joining step to manufacture a metal-resin composite member. A method for manufacturing a metal-resin composite, characterized by a process of joining a molded solid and a housing, wherein a metal-resin composite member having an annular projection formed on the outer circumference of the molded solid of the metal-resin composite member is fitted into an injection molding die, a thermoplastic resin of the same type as the molded solid is heated and melted and injected into the injection molding die to form a housing that is tightly bonded to the molten annular projection of the molded solid and covers the surface of the metal-resin composite member, thereby forming a space, and the metal member is placed in the space, thereby manufacturing a metal-resin composite.

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