Method for manufacturing a composite component and composite component

Abstract

Provided is a method for manufacturing a composite member in which an aluminum member and a resin member are joined together, the method including: a sandblasting process in which the surface of the aluminum member is subjected to sandblasting; a surface hydroxide process in which the surface of the aluminum member after the sandblasting is reacted with water vapor under a pressure exceeding atmospheric pressure to modify the surface of the aluminum member to aluminum hydroxide; and a joining process in which the resin member is directly joined to the surface of the aluminum member modified to aluminum hydroxide.

Description

Technical Field

[0001] This invention relates to a method for manufacturing composite components and to composite components. Background Technology

[0002] Patent Document 1 discloses a method for manufacturing a composite component. This method allows for the manufacture of a composite component formed by bonding a base material and a resin component. Micrometer- or nanometer-scale irregularities are formed on the surface of the base material. The resin component penetrates and cures within these micrometer- or nanometer-scale irregularities, resulting in a stronger anchoring effect compared to millimeter-scale irregularities. Therefore, the composite component manufactured using this method exhibits excellent bond strength.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: International Publication No. 2017 / 141381 Summary of the Invention

[0006] Compared to iron, aluminum is lighter and stronger. Therefore, it is used for various parts and is very suitable as a base material for composite components. From the viewpoint of further improving the bonding strength of composite components based on aluminum, the manufacturing method described in Patent Document 1 has room for improvement.

[0007] According to one aspect of the present invention, a method for manufacturing a composite component formed by bonding an aluminum component and a resin component can be provided. The manufacturing method includes a sandblasting process, a surface hydroxideing process, and a bonding process. In the sandblasting process, the surface of the aluminum component is sandblasted. In the surface hydroxideing process, a pressure exceeding atmospheric pressure is applied to cause the surface of the sandblasted aluminum component to react with water vapor, modifying the surface of the aluminum component into an aluminum hydroxide. In the bonding process, the resin component is directly bonded to the surface of the aluminum hydroxide-modified aluminum component.

[0008] According to this manufacturing method, the surface of the aluminum component is sandblasted. The sandblasted aluminum component has an uneven surface. This unevenness contributes to the anchoring effect. However, the unevenness is formed by the impact of the blasted material, thus becoming sharp protrusions. These sharp protrusions risk becoming the starting point for the resin component to fracture. According to this manufacturing method, the surface of the sandblasted aluminum component is modified to aluminum hydroxide. This rounds off the sharp protrusions. Then, the resin component can be directly bonded to the surface of the aluminum component modified to aluminum hydroxide. The resin component enters the smooth unevenness and cures. Thus, according to this manufacturing method, the sharp protrusions that could become the starting point for the resin component to fracture can be removed by a surface hydroxide process, thereby improving the bonding strength of the composite component. Furthermore, on the surface of the aluminum component, the oxygen atoms of the hydroxyl groups of the aluminum hydroxide form hydrogen bonds with the hydrogen atoms contained in the resin. Therefore, chemical bonds are formed between the surface of the aluminum component and the resin component, thus improving the bonding strength. Furthermore, the surface of the aluminum component formed from aluminum hydroxide has fine pores of tens to hundreds of nm. Therefore, this manufacturing method can enhance the anchoring effect. Furthermore, the aluminum component reacts with water vapor under pressure exceeding atmospheric pressure, thus, a portion of the surface of the aluminum component is modified, for example, into an amorphous layer containing aluminum and oxygen atoms. By forming the amorphous layer, the inherent potential difference between the materials of the aluminum component and the resin component can be suppressed, and corrosion of the aluminum component due to electrochemical action can be inhibited. Therefore, this manufacturing method can stably maintain the bonding strength of the composite component.

[0009] In one embodiment, the surface hydroxide process involves applying heat above 140°C to react the surface of the sandblasted aluminum component with water vapor. In this case, the manufacturing method can easily modify the surface of the aluminum component into an aluminum hydroxide. Furthermore, since the surface of the aluminum component is heat-treated, precipitation and solidification occur. Therefore, this manufacturing method can increase the hardness of the composite component.

[0010] In one embodiment, the surface hydroxide process involves reacting the surface of the sandblasted aluminum component with water vapor for a treatment time of 2 hours to 24 hours. In this case, the manufacturing method can form a layer of aluminum hydroxide of appropriate density on the surface of the aluminum component.

[0011] In one embodiment, the aluminum hydroxide may include at least one of diaspore, boehmite, pseudoboehmite, Bayerite, Nordstrandite, gibbsite, and doyleite.

[0012] In one embodiment, the abrasive grains used in the sandblasting process can have a particle size of 30 μm to 710 μm. In this case, the manufacturing method can appropriately remove the oxide film formed on the surface of the aluminum component, thus forming a uniform layer of aluminum hydroxide on the surface of the aluminum component.

[0013] In one embodiment, the resin component may contain a conductive filler, thus exhibiting conductivity. Based on this configuration, a composite component formed by bonding a conductive resin component to an aluminum component can be obtained. The bonding portion between the aluminum component and the resin component forms an amorphous layer containing aluminum and oxygen atoms. This suppresses the inherent potential difference between the materials of the aluminum and resin components, and inhibits corrosion of the aluminum component due to electrochemical reactions. Therefore, with this manufacturing method, even if the resin component is conductive, the bonding strength of the composite component can be stably maintained. Thus, this manufacturing method increases the freedom of choice in selecting the material of the resin component.

[0014] According to other aspects of the invention, a composite component can be provided. The composite component comprises: an aluminum component having an uneven surface, and a resin component in direct contact with the surface of the aluminum component. The surface of the aluminum component comprises: a precipitated layer disposed on a base aluminum material containing alloying elements precipitated from the base material; an amorphous layer disposed on the precipitated layer containing aluminum atoms and oxygen atoms; and a contact layer disposed on the amorphous layer containing aluminum hydroxide and in direct contact with the resin component. It should be noted that the base aluminum material may also include a precipitated layer containing alloying elements contained in the base material.

[0015] In this composite component, the surface of the aluminum component in direct contact with the resin component has an uneven surface, thus providing an anchoring effect. Furthermore, a contact layer containing aluminum hydroxide is formed on the surface of the aluminum component. The oxygen atoms of the hydroxyl groups in the aluminum hydroxide contained in the contact layer form hydrogen bonds with the hydrogen atoms contained in the resin. Therefore, chemical bonds are formed between the surface of the aluminum component and the resin component, thus improving the bonding strength of the composite component. Furthermore, the contact layer on the surface of the aluminum component has pores of tens to hundreds of nm. Therefore, the composite component enhances the anchoring effect. In addition, an amorphous layer containing aluminum atoms and oxygen atoms is formed on the surface of the aluminum component. Therefore, the inherent potential difference between the materials of the aluminum component and the resin component can be suppressed, corrosion of the aluminum component due to electrochemical action can be suppressed, and the composite component can stably maintain the bonding strength. Furthermore, a precipitation layer is formed on the surface of the aluminum component. In the precipitation layer, alloying elements precipitate from the aluminum substrate, resulting in precipitation solidification, thus improving the hardness of the composite component.

[0016] In one embodiment, the aluminum hydroxide may include at least one of diaspore, boehmite, pseudoboehmite, Bayerite, notrihydrate, gibbsite, and diaspore.

[0017] In one embodiment, the resin component may contain a conductive filler, thus exhibiting conductivity. Based on this configuration, a composite component formed by bonding a conductive resin component to an aluminum component can be obtained. An amorphous layer containing aluminum and oxygen atoms is formed at the bonding portion between the aluminum and resin components. This suppresses the inherent potential difference between the materials of the aluminum and resin components, and inhibits corrosion of the aluminum component due to electrochemical reactions. Therefore, in this composite component, even if the resin component is conductive, the bonding strength of the composite component can be stably maintained. Thus, this composite component increases the freedom of choice in selecting the material of the resin component.

[0018] According to one aspect and embodiment of the present invention, a method for manufacturing a composite component with excellent bonding strength, and a composite component with excellent bonding strength, can be provided. Attached Figure Description

[0019] Figure 1 This is a perspective view showing the composite component involved in the implementation method.

[0020] Figure 2 For along Figure 1 A cross-sectional view of the composite component of line II-II.

[0021] Figure 3 This is a conceptual diagram of a sandblasting apparatus used in the manufacturing method of the composite component according to the embodiment.

[0022] Figure 4 A diagram illustrating the configuration of the sandblasting apparatus used in the manufacturing method of the composite component according to the embodiment.

[0023] Figure 5 for Figure 4 A cross-sectional view of the injection nozzle.

[0024] Figure 6 This is a top view of the mold used for pressing and molding.

[0025] Figure 7 For along Figure 6 A cross-sectional view of the mold for line VII-VII.

[0026] Figure 8 This is a flowchart illustrating a method for manufacturing a composite component according to an embodiment.

[0027] Figure 9 This is a conceptual diagram of sandblasting.

[0028] Figure 10 A scanned image used to illustrate the sandblasting process.

[0029] Figure 11 A diagram illustrating the manufacturing process of composite components.

[0030] Figure 12 The results of surface observation of aluminum components.

[0031] Figure 13 The crystal structure analysis results are for the surface of the aluminum component.

[0032] Figure 14 The results of surface observation of aluminum components.

[0033] Figure 15 The crystal structure analysis results are for the surface of the aluminum component.

[0034] Figure 16 The results are for the processing conditions and shear strength involved in the examples.

[0035] Figure 17 The results show the Vickers hardness of the aluminum components.

[0036] Explanation of reference numerals in the attached figures

[0037] 1…composite component, 2…aluminum component, 2a…surface, 2b…uneven surface, 2c…base material, 2d…precipitated layer, 2e…amorphous layer, 2f…contact layer, 3…resin component, 10…sandblasting device, 11…processing chamber, 12…spray nozzle, 13…storage tank, 14…pressurization chamber, 15…compressed gas supply machine, 16…quantitative supply unit, 17…connecting pipe, 18…processing table, 19…control unit, 20…mold, 21…mold body. Detailed Implementation

[0038] The embodiments will now be described with reference to the illustrations. It should be noted that in the following description, the same or equivalent elements are labeled with the same symbols, and repeated descriptions are omitted. Furthermore, in this embodiment, "bonding strength" is described as "shear strength".

[0039] [Composite Components]

[0040] Figure 1 This is a perspective view showing the composite component 1 according to the embodiment. (See attached image.) Figure 1 As shown, composite component 1 is a component that integrates multiple components by joining them together. For example, composite component 1 is a component formed by joining a resin component and a component of a different type from the resin component. The component of a different type from the resin component refers to a component formed of a material with different properties relative to the resin component, such as coefficient of thermal expansion, thermal conductivity, and strength.

[0041] Composite component 1 comprises an aluminum component 2 and a resin component 3. As an example, the aluminum component 2 is a plate-shaped component. The resin component 3 is in direct contact with the surface of the aluminum component 2. Figure 1In this structure, resin component 3 is in direct contact with a portion of the surface of aluminum component 2 (contact surface 4 of aluminum component 2), forming an overlapping joint structure. The material of aluminum component 2 is an aluminum alloy.

[0042] The resin component 3 contains a conductive filler and may be a conductive resin. For example, the resin component 3 may contain a carbon-based material as a conductive filler comprising at least one of the following: powder of conductive carbon black such as Ketjen black; sheets comprising at least one of graphite and graphene sheets; ultrashort fibers of carbon nanotubes; and fibers of carbon fiber reinforced thermoplastic resin (CFRTP). The resin component 3 may also contain a metallic material as a conductive filler comprising at least one of the following: powder comprising at least one of gold (Au), silver (Ag), nickel (Ni), copper (Cu), zinc (Zn), aluminum (Al), and stainless steel; sheets comprising at least one of silver (Ag), nickel (Ni), copper (Cu), zinc (Zn), aluminum (Al), and stainless steel; and fibers comprising at least one of copper (Cu), stainless steel, and brass.

[0043] The resin component 3 may, for example, have a metal oxide material comprising at least one of the following as a conductive filler: antimony (Sb)-doped tin oxide (SnO2), tin-doped indium oxide (In2O3), and aluminum-doped zinc oxide (ZnO). The resin component 3 may also have a metal coating material as a conductive filler, wherein the metal coating material uses at least one of nickel (Ni) and aluminum (Al) as the coating material, and includes powders and fibers comprising at least one of mica, glass beads, glass fibers, carbon fibers, calcium carbonate, zinc oxide, and titanium oxide as the base filler. The resin component 3 may comprise at least one of the above-mentioned carbon-based materials, metal-based materials, metal oxide materials, and metal coating materials.

[0044] The resin component 3 may also be a conductive resin without containing conductive fillers. In this case, for example, the material of the resin component 3 may be a resin such as polybutylene terephthalate, polyphenylene sulfide, polyamide, liquid crystal polymer, polypropylene, acrylonitrile butadiene styrene, etc.

[0045] Figure 2 For along Figure 1 A cross-sectional view of composite component 1 along line II-II. (See attached image.) Figure 2As shown, the aluminum component 2 has an unevenness 2b on a portion of its surface 2a (contact surface 4). The unevenness 2b is either micron-scale or nanon-scale. Micron-scale unevenness refers to unevenness with a height difference of 1 μm or more but less than 1000 μm. Nanon-scale unevenness refers to unevenness with a height difference of 1 nm or more but less than 1000 nm. The ends of the unevenness 2b are chamfered. Therefore, the unevenness 2b becomes smooth and has no sharp parts. The resin component 3 is inserted into the unevenness 2b and fixed therein, thus providing an anchoring effect.

[0046] Furthermore, the surface 2a of the aluminum component 2 has: a precipitated layer 2d disposed on the aluminum substrate 2c, an amorphous layer 2e disposed on the precipitated layer 2d, and a contact layer 2f disposed on the amorphous layer 2e. The substrate 2c is mainly composed of aluminum atoms, and the precipitated layer 2d is formed on the upper part of a portion thereof.

[0047] The precipitated layer 2d is formed by heat treatment to precipitate aluminum alloying elements such as silicon (Si) or magnesium (Mg) from the base material 2c of the aluminum component 2. The precipitated layer 2d is disposed on the base material 2c. In the three-layer structure of the precipitated layer 2d, the amorphous layer 2e, and the contact layer 2f, the precipitated layer 2d is located on the side closest to the base material 2c. It should be noted that the aluminum base material 2c may contain the precipitated layer, which contains the aluminum alloying elements contained in the base material 2c. For example, through heat treatment, the base material 2c present near the precipitated layer 2d can contain the same amount of aluminum alloying elements as the precipitated layer 2d.

[0048] The amorphous layer 2e is an amorphous layer containing aluminum and oxygen atoms. The amorphous layer 2e can be, for example, composed of dense aluminum oxide (Al2O3). The amorphous layer 2e is located above the precipitated layer 2d (closer to the resin component 3 than the precipitated layer 2d), and has a thickness of, for example, tens of nm to several μm.

[0049] Contact layer 2f comprises aluminum hydroxide and is in direct contact with resin component 3. Contact layer 2f is located above amorphous layer 2e (closer to resin component 3 than amorphous layer 2e). Contact layer 2f is exposed on the surface, which has pores of tens to hundreds of nm in size. The aluminum hydroxide is an aluminum compound containing hydroxyl groups. The aluminum hydroxide comprises at least one of diaspore, boehmite, pseudoboehmite, bayerite, nostilbene, gibbsite, and diaspore. The aluminum hydroxide may comprise any one of diaspore, boehmite, pseudoboehmite, bayerite, nostilbene, gibbsite, and diaspore. The aluminum hydroxide may also comprise multiple aluminum hydroxides selected from diaspore, boehmite, pseudoboehmite, bayerite, nostilbene, gibbsite, and diaspore.

[0050] The resin component 3 is joined to the aluminum component 2 with a portion of it entering the concave-convex 2b. Such a structure can be formed by injection molding using the mold 20 described later. It should be noted that the composite component 1 can also be joined by methods other than injection molding, such as ultrasonic bonding, compression molding, or vibration bonding.

[0051] As described above, the composite component 1 of this embodiment has an uneven surface 2b on the surface 2a of the aluminum component 2, which is in direct contact with the resin component 3, thus providing an anchoring effect. Furthermore, the surface 2a of the aluminum component 2 has a precipitated layer 2d, an amorphous layer 2e, and a contact layer 2f. The oxygen atoms of the hydroxyl groups in the aluminum hydroxide contained in the contact layer 2f form hydrogen bonds with the hydrogen atoms contained in the resin. Therefore, chemical bonds are formed between the surface 2a of the aluminum component 2 and the resin component 3, thereby improving the bonding strength. Furthermore, the contact layer 2f in the surface 2a of the aluminum component 2 has pores of tens to hundreds of nm, thus enhancing the anchoring effect. Therefore, the composite component 1 has excellent bonding strength. In addition, an amorphous layer 2e containing aluminum atoms and oxygen atoms is formed on the surface 2a of the aluminum component 2. Therefore, the inherent potential difference between the materials of the aluminum component 2 and the resin component 3 can be suppressed, and corrosion of the aluminum component 2 due to electrochemical action can be suppressed. Therefore, the composite component 1 can stably maintain the bonding strength. Furthermore, a precipitated layer 2d is formed on the surface 2a of the aluminum component 2. In the precipitated layer 2d, precipitation solidification occurs through the precipitation of alloying elements from the aluminum matrix 2c, thus improving the hardness of the composite component 1.

[0052] [Manufacturing Method of Composite Components]

[0053] The apparatus used in the manufacturing method of composite component 1 will be described in general. First, the apparatus for sandblasting the surface of aluminum component 2 will be described. The sandblasting apparatus can be any type, such as a gravity-type (suction-type) air sandblasting apparatus, a direct-pressure (pressurized) air sandblasting apparatus, or a centrifugal sandblasting apparatus. In the manufacturing method according to this embodiment, as an example, a so-called direct-pressure (pressurized) air sandblasting apparatus is used. Figure 3 This is a conceptual diagram of a sandblasting apparatus 10 used in the manufacturing method of composite component 1. The sandblasting apparatus 10 includes a processing chamber 11, a blasting nozzle 12, a storage tank 13, a pressurization chamber 14, a compressed gas supply unit 15, and a dust collector (not shown).

[0054] The processing chamber 11 houses the blasting nozzle 12, within which the workpiece (here, aluminum component 2) is sandblasted. The blasting material ejected by the nozzle 12, along with dust, falls to the lower part of the processing chamber 11. The fallen blasting material is supplied to a storage tank 13, and the dust is supplied to a dust collector. The blasting material stored in the storage tank 13 is supplied to a pressurization chamber 14, which is pressurized by a compressed gas supply unit 15. The blasting material stored in the pressurization chamber 14, along with compressed gas, is then supplied to the blasting nozzle 12. In this manner, the blasting material is circulated while the workpiece is sandblasted.

[0055] Figure 4 This diagram illustrates the configuration of the sandblasting apparatus 10 used in the manufacturing method of the composite component 1 according to the embodiment. Figure 4 The sandblasting device 10 shown is Figure 3 The direct-pressure sandblasting device shown is shown. Figure 4 In the diagram, a portion of the wall of the processing chamber 11 is omitted from the representation.

[0056] like Figure 4 As shown, the sandblasting apparatus 10 includes: a storage tank 13 and a pressurization chamber 14 for blasting material connected to a compressed gas supply 15 and forming a sealed structure; a metering supply unit 16 communicating with the storage tank 13 inside the pressurization chamber 14; a blasting nozzle 12 communicating with the metering supply unit 16 via a connecting pipe 17; a processing table 18 that holds the workpiece below the blasting nozzle 12 and is movable; and a control unit 19.

[0057] The control unit 19 controls the constituent elements of the sandblasting apparatus 10. As an example, the control unit 19 includes a display unit and a processing unit. The processing unit is a typical computer with a CPU and storage unit. Based on the set jet pressure and jet speed, the control unit 19 controls the amount of compressed gas supplied by the compressed gas supply unit 15 to the storage tank 13 and the pressurization chamber 14, respectively. Furthermore, the control unit 19 controls the jet position of the jet nozzle 12 based on the set distance between the workpiece and the nozzle and the workpiece scanning conditions (speed, transport distance, number of scans, etc.). As a specific example, the control unit 19 uses the scanning speed (X direction) and transport distance (Y direction) set before the sandblasting process to control the position of the jet nozzle 12. The control unit 19 controls the position of the jet nozzle 12 by moving the processing table 18 that holds the workpiece.

[0058] Figure 5 for Figure 4A cross-sectional view of the injection nozzle 12. The injection nozzle 12 has a main body, namely an injection tube support 120. The injection tube support 120 is a cylindrical member with an internal space for the injection material and compressed gas to pass through. One end of the injection tube support 120 is an injection material inlet 123, and the other end is an injection material outlet 122. Inside the injection tube support 120, a conical inner wall surface is formed from the injection material inlet 123 side toward the injection material outlet 122, and is composed of a conical converging acceleration section 121 with an inclined angle. A cylindrical injection tube 124 is provided in communication with the injection material outlet 122 side of the injection tube support 120. The converging acceleration section 121 forms a cone shape from the middle of the cylindrical part of the injection tube support 120 toward the injection tube 124. As a result, a compressed gas flow 115 is formed.

[0059] A connecting pipe 17 of the sandblasting device 10 is connected to the material inlet 123 of the spray nozzle 12. This forms a material spraying path that sequentially connects the storage tank 13, the metering supply unit 16 in the pressurization chamber 14, the connecting pipe 17, and the spray nozzle 12.

[0060] The sandblasting apparatus 10 configured in this way supplies compressed gas, controlled by the control unit 19, to the storage tank 13 and the pressurization chamber 14 from the compressed gas supply unit 15. Then, using a constant pressure flow, the abrasive material in the storage tank 13 is metered in the metering supply unit 16 within the pressurization chamber 14 and supplied to the abrasive nozzle 12 via the connecting pipe 17. The abrasive material is then sprayed onto the workpiece's machining surface through the spray pipe of the abrasive nozzle 12. This allows for a continuous and constant supply of abrasive material to the workpiece's machining surface. The control unit 19 then controls the spray position of the abrasive nozzle 12 on the workpiece's machining surface, performing sandblasting on the workpiece.

[0061] Furthermore, the blasting material and cutting powder generated during sandblasting are attracted by a dust collector (not shown). A classifier (not shown) is configured along the path from the processing chamber 11 to the dust collector to separate reusable blasting material from other fine powders (blasting material reduced to a size that is no longer usable, and cutting powder generated during sandblasting). The reusable blasting material is collected in a storage tank 13 and then fed back to the blasting nozzle 12. The fine powders are recovered by the dust collector.

[0062] Next, injection molding will be explained. Here, insert molding can be used for injection molding. In insert molding, an insert is installed on a specified mold, resin is injected, and it is held for a specified time to cure. Subsequently, residual stress in the resin is removed by heat treatment. Figure 6 This is a top view of a mold used for injection molding. Figure 7 For along Figure 6 A cross-sectional view of the mold for line VII-VII. (See attached image.) Figure 6 , Figure 7As shown, mold 20 includes mold body 21 (upper mold 21a and lower mold 21b). Between upper mold 21a and lower mold 21b, there is a space 22 for mounting inserts (here, aluminum component 2) and a space 23 for injecting resin. A resin injection port is provided on the upper mold 21a. The resin injection port communicates with space 23 via sprue 24, runner 25, and gate 26. A pressure sensor 27 and a temperature sensor 28 are provided in space 23 to detect the pressure and temperature of space 23. Based on the detection results of pressure sensor 27 and temperature sensor 28, the parameters of a molding machine (not shown) are adjusted to manufacture a molded article. The parameters include mold temperature, resin temperature during filling, filling pressure, injection rate, holding time, holding pressure, heat treatment temperature, and heat treatment time. The molded article formed by mold 20 is an overlapping joint structure joined by a specified area.

[0063] Next, a series of processes for manufacturing composite component 1 will be described. Figure 8 This is a flowchart of the manufacturing method MT for the composite component 1 according to the embodiment. Figure 8 As shown, firstly, as a preparation step (S10), a specified abrasive material is filled into the sandblasting apparatus 10. The particle size of the abrasive material (abrasive grains) is, for example, 30 μm to 710 μm. The smaller the particle size of the abrasive material, the smaller its mass, and therefore the inertial force is reduced. Therefore, when the particle size of the abrasive material is less than 30 μm, it is difficult to form the desired shape of the unevenness 2b. Furthermore, industrially used aluminum components 2 are usually stored in the atmosphere, and their surfaces are covered with an uneven aluminum amorphous oxide film with a thickness of 60 nm to 300 nm. Therefore, surface etching and surface laser processing using reagents risk becoming uneven surface treatments due to the presence of the aluminum amorphous oxide film. In the surface hydroxide process (S14) described later, in order to uniformly modify the surface 2a of the aluminum component 2, it is necessary to make the aluminum amorphous oxide film with a thickness of about 30 nm or less. However, when the particle size of the abrasive material exceeds 710 μm, it is difficult to reduce the aluminum amorphous oxide film to a thickness of about 30 nm or less. Therefore, it is impossible to completely remove the aluminum oxide formed on the surface of the aluminum component 2. The abrasive grains with a diameter of 30 μm to 710 μm are used to achieve both the formation of unevenness and the removal of the amorphous oxide film of aluminum.

[0064] The control unit 19 of the sandblasting apparatus 10 acquires the sandblasting conditions as a preparation step (S10). The control unit 19 acquires the sandblasting conditions based on the operator's operation or information stored in the storage unit. The sandblasting conditions include the blasting pressure, blasting speed, nozzle spacing, and workpiece scanning conditions (speed, transport distance, number of scans), etc. The blasting pressure is, for example, 0.5 to 2.0 MPa. The lower the blasting pressure, the lower the inertial force. Therefore, when the blasting pressure is less than 0.5 MPa, it is difficult to form the desired shape of the concave-convex 2b. The higher the blasting pressure, the higher the inertial force. Therefore, the blasted material is easily crushed by collision with the aluminum component 2. As a result, (1) the energy of the collision is dispersed beyond the formation of the concave-convex 2b, resulting in poor processing efficiency, and (2) excessive loss of blasted material, resulting in poor economy. Such problems are more pronounced when the blasting pressure exceeds 2.0 MPa. The control unit 19 manages the sandblasting conditions to precisely control the size, depth, density, etc. of the unevenness 2b of the surface 2a of the aluminum component 2 at the micron or nanometer level. It should be noted that the sandblasting conditions may also include conditions for defining the area to be sandblasted. In this case, selective surface treatment can be achieved. Furthermore, in the preparation step (S10), the aluminum component 2 can be ultrasonically cleaned using ethanol or the like for a predetermined time.

[0065] Next, the sandblasting apparatus 10 performs the following series of processes as a sandblasting step (S12). First, the aluminum component 2, which is to be sandblasted, is placed on the processing table 18 inside the processing chamber 11. Next, the control unit 19 operates a dust collector (not shown). Based on the control signal from the control unit 19, the dust collector depressurizes the interior of the processing chamber 11 to a negative pressure state. Next, based on the control signal from the control unit 19, the spray nozzle 12 sprays the spray material as a solid-gas two-phase flow of compressed air within a spray pressure range of 0.5 to 2.0 MPa. Next, the control unit 19 operates the processing table 18, causing the aluminum component 2 to be immersed in the solid-gas two-phase flow spray ( Figure 4 (Moves below the spray nozzle). Figure 9 This is a conceptual diagram of sandblasting. (Example:) Figure 9 As shown, spray material is sprayed from the spray nozzle 12 onto a portion 2g of the surface 2a of the aluminum component 2. Here, the control unit 19 keeps the operation of the processing table 18 running, causing it to operate in a manner that traces a preset trajectory on the aluminum component 2 with the spray stream. Figure 10 A scanned image illustrating the sandblasting process. (See image below.) Figure 10 As shown, the control unit 19 causes the processing table 18 to operate along a trajectory L that is scanned at a transport pitch P. This forms the desired micron- or nanometer-scale unevenness 2b on the surface of the aluminum component 2.

[0066] Using a blasting material with a particle size of 30–710 μm, sandblasting is performed at a blasting pressure ranging from 0.5 to 2.0 MPa, thereby forming desired micron- or nanometer-scale unevenness 2b on the surface 2a of the aluminum component 2 (for example, the arithmetic mean slope RΔa and root mean square slope RΔq specified in JIS (Japanese Industrial Standard) B 0601 (1994) are controlled to be 0.17–0.50 and 0.27–0.60, respectively). Furthermore, the amorphous oxide film on the surface of the aluminum component 2 becomes a film with a thickness of approximately 9 nm or less. After the operation of the sandblasting apparatus 10 stops, the aluminum component 2 is removed, and the sandblasting process is completed.

[0067] Figure 11 A diagram illustrating the manufacturing process of a composite component. (For example...) Figure 11 As shown in (A), the surface 2a of the sandblasted aluminum component 2 has a sharp protrusion 2b.

[0068] Next, as a surface hydroxide process (S14), pressure exceeding atmospheric pressure is applied to react the surface 2a of the sandblasted aluminum component 2 with water vapor, modifying the surface 2a of the aluminum component 2 into aluminum hydroxide. In the surface hydroxide process (S14), water vapor treatment is used to react the surface 2a of the aluminum component 2 with water vapor. In the water vapor treatment, the sandblasted aluminum component 2 and water are placed inside a pressure vessel, heated to above 140°C, and pressure exceeding atmospheric pressure is applied, thereby filling the pressure vessel with water vapor. The pressure vessel is, for example, an autoclave.

[0069] Therefore, as Figure 11 As shown in (B), the unevenness 2b becomes smooth. Furthermore, a three-layer structure consisting of a precipitated layer 2d, an amorphous layer 2e, and a contact layer 2f is formed on the surface 2a of the aluminum component 2.

[0070] In the steam treatment, the sandblasted aluminum component 2 is exposed to steam heated to above 140°C for a specified period, thereby heating the surface 2a of the aluminum component 2, thus forming a precipitation layer 2d on the base material 2c of the aluminum component 2. In the precipitation layer 2d, aluminum alloying elements such as silicon (Si) or magnesium (Mg) are precipitated from the base material 2c and solidified.

[0071] By applying pressure exceeding atmospheric pressure, water vapor is used to oxidize the surface 2a of the aluminum component 2, thus forming an amorphous layer 2e on top of the precipitated layer 2d (on the side closer to the resin component 3 than the precipitated layer 2d). The amorphous layer 2e is an amorphous layer containing aluminum atoms and oxygen atoms. The amorphous layer 2e is, for example, composed of dense aluminum oxide (Al2O3).

[0072] By applying pressure exceeding atmospheric pressure, water vapor is used to oxidize the surface of the aluminum component 2a, thus forming a contact layer 2f on top of the amorphous layer 2e (on the side closer to the resin component 3 than the amorphous layer 2e). The contact layer 2f contains aluminum hydroxide. The aluminum hydroxide of the contact layer 2f primarily contains boehmite. The aluminum hydroxide of the contact layer 2f is not limited to boehmite and may contain any one of diaspore, pseudoboehmite, bayonet, notsia gibbsite, gibbsite, and diaspore. The aluminum hydroxide of the contact layer 2f may also contain a variety of aluminum hydroxides selected from diaspore, boehmite, pseudoboehmite, bayonet, notsia gibbsite, gibbsite, and diaspore.

[0073] It should be noted that, from the viewpoint of pressure vessel durability, the pressure applied to aluminum component 2 and water is set to be higher than atmospheric pressure (0.1013 MPa) and lower than 3.0 MPa. The aluminum component 2 and water vapor react for at least 2 hours and within 24 hours, for example, from the moment the specified heating temperature of 140°C or higher is reached. Furthermore, in the surface hydroxide process (S14), the surface of the aluminum component can be cleaned with water. In this case, cleaning the surface of the aluminum component with water can reduce the surface carbon concentration.

[0074] Next, as part of the joining process (S16), a molding machine (not shown) performs injection molding using the mold 20 described above. First, the mold 20 is opened, and an aluminum component 2 with a three-layer structure consisting of a precipitation layer 2d, an amorphous layer 2e, and a contact layer 2f is installed in the space 22. The mold 20 is then closed. Next, the molding machine injects molten resin at a set resin temperature into the interior of the mold 20 through the resin injection port. The injected resin fills the space 23 through the sprue 24, runner 25, and gate 26. The molding machine controls the resin filling pressure and injection rate based on the detection results of the pressure sensor 27. The molding machine controls the mold temperature to a set value based on the detection results of the temperature sensor 28. Furthermore, the molding machine controls the pressure to a set value for a set holding time based on the detection results of the pressure sensor 27. Afterward, the molding machine performs heat treatment based on a set heat treatment temperature and time. Subsequently, the mold 20 is opened in the molding machine, and the composite component 1, which is formed by integrating the three-layer structure of the precipitated layer 2d, the amorphous layer 2e, and the contact layer 2f, the aluminum component 2, and the resin component 3, is removed. If the bonding process (S18) is completed, then Figure 8 The flowchart shown ends here. Therefore, it is possible to manufacture... Figure 11 Composite component 1 is shown in (C).

[0075] As described above, the surface 2a of the aluminum component 2 is sandblasted according to manufacturing method MT. After sandblasting, the surface 2a of the aluminum component 2 has a rough surface 2b with sharp protrusions. Subsequently, the surface 2a of the sandblasted aluminum component 2 is modified to an aluminum hydroxide primarily composed of boehmite. This rounds off the sharp protrusions. Then, the resin component 3 is directly bonded to the surface 2a of the aluminum component 2 modified with aluminum hydroxide. The resin component 3 penetrates the smooth rough surface 2b and cures. In this way, according to manufacturing method MT, the sharp protrusions that could become the starting point for fracture of the resin component 3 can be removed by the surface hydroxide process (S14), thus improving the bonding strength of the composite component 1.

[0076] Furthermore, in the contact layer 2f formed on the surface 2a of the aluminum component 2, hydrogen bonds are mainly formed between the oxygen atoms of the hydroxyl groups of boehmite and the hydrogen atoms contained in the resin. Therefore, chemical bonds are formed between the surface 2a of the aluminum component 2 and the resin component 3, thereby improving the bonding strength. Furthermore, the contact layer 2f in the surface 2a of the aluminum component 2, which is mainly composed of boehmite, has pores of tens to hundreds of nm. Therefore, the anchoring effect can be enhanced. Furthermore, the aluminum oxide film formed on the surface 2a of the aluminum component 2 is removed by sandblasting. The aluminum oxide film is the main factor hindering the formation of the contact layer 2f. According to manufacturing method MT, the aluminum oxide film is removed before the formation of aluminum hydroxide; therefore, the surface 2a of the aluminum component 2 can be modified into a homogeneous aluminum hydroxide.

[0077] Furthermore, in the surface hydroxide process (S14), the aluminum component 2 reacts with water vapor under pressure exceeding atmospheric pressure. As a result, a portion of the surface 2a of the aluminum component 2 is modified into an amorphous layer 2e containing aluminum and oxygen atoms. Therefore, the inherent potential difference between the materials of the aluminum component 2 and the resin component 3 can be suppressed, corrosion of the aluminum component 2 caused by electrochemical action can be suppressed, and the composite component 1 can stably maintain its bonding strength.

[0078] According to manufacturing method MT, in the surface hydroxideing process (S14), heat of 140°C or higher is applied to cause the surface 2a of the aluminum component 2 to react with water vapor. Therefore, the surface 2a of the aluminum component 2 can be easily modified into a contact layer 2f. Furthermore, the surface 2a of the aluminum component 2 is heat-treated, thereby forming a precipitation layer 2d. In the precipitation layer 2d, alloying elements precipitate from the aluminum substrate 2c, resulting in precipitation solidification. Therefore, in this manufacturing method, the hardness of the composite component 1 can be improved.

[0079] According to manufacturing method MT, in the surface hydroxide process (S14), the surface 2a of aluminum component 2 is reacted with water vapor for more than 2 hours and less than 24 hours, thereby forming a contact layer 2f of appropriate density on the surface 2a of aluminum component 2.

[0080] The contact layer 2f comprises at least one of diaspore, boehmite, pseudoboehmite, bayonetite, gibbsite, trihydrate, and diaspore. Among the aforementioned aluminum hydroxides, the contact layer 2f composed of a combination of multiple aluminum hydroxides, compared to the contact layer 2f composed of any single aluminum hydroxide, can be formed in the surface hydroxide process (S14) while keeping the temperature of the heated aluminum component 2 and water low.

[0081] According to manufacturing method MT, the surface 2a of the aluminum component 2 is cleaned with water, thus suppressing the reduction in bonding strength caused by carbon contamination. According to manufacturing method MT, by setting the particle size of the abrasive grains used in the sandblasting process to 30 μm to 710 μm, the oxide film formed on the surface 2a of the aluminum component 2 can be appropriately removed, thus forming a uniform contact layer 2f on the surface 2a of the aluminum component 2. Furthermore, by setting the particle size of the abrasive grains used in the sandblasting process to the aforementioned range, an uneven surface 2b with an appropriate arithmetic mean slope can be formed on the surface 2a of the aluminum component 2.

[0082] According to manufacturing method MT, in the surface hydroxideing process (S14), an amorphous layer 2e is formed on the surface 2a of the aluminum component 2. This suppresses the inherent potential difference between the materials of the aluminum component 2 and the resin component 3, and inhibits corrosion of the aluminum component 2 caused by electrochemical action. Therefore, in this manufacturing method MT, even if the resin component 3 is a conductive component, the bonding strength of the composite component 1 can be stably maintained. Thus, this manufacturing method MT can increase the freedom of choice in selecting the material of the resin component 3.

[0083] The present invention has been described above, but it is not limited to the present invention described above. It is self-evident that various modifications can be made outside the present invention without departing from its spirit.

[0084] [Examples of deformation in the base material and resin components]

[0085] The aluminum component 2 and resin component 3 described in the above embodiments are illustrated using a plate-shaped component as an example, but the shape is not limited, and any shape that can contact each other can be used. The resin component 3 described in the above embodiments contacts a portion of the surface of the aluminum component 2, but it can also contact the entire surface of the aluminum component 2.

[0086] [Examples of joint variations]

[0087] The joining of aluminum component 2 and resin component 3 can be achieved through compression molding. In compression molding, aluminum component 2 and resin component 3 are fixed by a mold, thus improving the dimensional accuracy of the joined composite component 1 compared to other joining methods. Alternatively, the joining of aluminum component 2 and resin component 3 can also be achieved through ultrasonic bonding. In ultrasonic bonding, a molding machine can subject at least one of aluminum component 2 and resin component 3 to ultrasonic vibration to join them. In ultrasonic bonding, only the joint between aluminum component 2 and resin component 3 is heated, thus suppressing warping of the joined composite component 1 caused by the difference in thermal expansion rates between aluminum component 2 and resin component 3.

[0088] Example

[0089] [Abrasive particle size of the jetting material]

[0090] First, the thickness of the oxide film on aluminum component 2 before the sandblasting process (S12) was measured. Depth-direction analysis of the aluminum oxide film was performed using Auger electron spectroscopy (AES). Oxide and metal components were detected simultaneously near the oxide / metal interface; therefore, they were separated using spectroscopic synthesis to determine the oxide film thickness. The oxide film thickness was 72 nm. Next, using... Figures 3-5 The sandblasting apparatus shown performs a sandblasting process (S12), and then measures the thickness of the oxide film on the aluminum component 2. When using a blasting material with a central abrasive particle size of 600 μm to 710 μm, the oxide film thickness is 13 nm. When using a blasting material with a central abrasive particle size of 41 μm to 50 μm (maximum particle size 127 μm or less, average particle size 57 μm ± 3 μm), the oxide film thickness is 9 nm. Therefore, it can be confirmed that by using a blasting material with a particle size of at least 710 μm or less, the oxide film on the surface 2a of the aluminum component 2 can be removed.

[0091] [Confirmation of the surface condition and surface roughness of aluminum components under varying heating temperatures]

[0092] Aluminum components are made of aluminum sheet (JIS: A5052). A surface hydroxide treatment process (S14) is performed on the aluminum components. As part of the surface hydroxide treatment (S14), 10 ml of pure water is added to an autoclave, the aluminum sheet is placed inside, and steam treatment is performed for 24 hours. Hereinafter, the steam treatment time is sometimes referred to simply as "treatment time." The heating temperatures for the steam treatment are 140°C, 180°C, and 220°C. It should be noted that the pressure inside the autoclave is 0.5 MPa at a heating temperature of 140°C, 1.0 MPa at a heating temperature of 180°C, and 2.3 MPa at a heating temperature of 220°C. Then, the surface roughness is confirmed by observing the surface using a field emission scanning electron microscope (FE-SEM).

[0093] Figure 12 The results of surface observation of aluminum components. Figure 12 (A), (B), and (C) are surface observation results of aluminum plates after surface hydroxide processing (S14) at 140℃, 180℃, and 220℃, respectively. It can be confirmed that: Figure 12 As shown in (A), (B), and (C), the protrusions on the aluminum component grow larger as the heating temperature increases during the surface hydroxide process (S14).

[0094] Figure 13 The crystal structure analysis results of the surface of the aluminum component (X-ray diffraction measurement). Figure 13 In the diagram, the vertical axis represents the intensity of the diffracted X-rays, and the horizontal axis represents the diffraction angle. For example... Figure 13 As shown, X-ray diffraction analysis of the aluminum component to determine its crystal structure revealed diffraction peaks for aluminum (Al), basic alumina (AlO(OH)), and magnesium silicide (Mg₂Si). This clearly indicates that the surface of the aluminum component contains aluminum, basic alumina, and magnesium silicide. Furthermore, the higher the heating temperature, the more pronounced the diffraction peaks of basic alumina become. This confirms that higher heating temperatures lead to greater growth of basic alumina.

[0095] Furthermore, the surface roughness of the aforementioned aluminum components was measured according to the arithmetic mean roughness Ra specified in JIS B 0601 (1994). The arithmetic mean roughness Ra of the aluminum components heated at 140°C was 0.42 μm, the arithmetic mean roughness Ra of the aluminum components heated at 180°C was 0.56 μm, and the arithmetic mean roughness Ra of the aluminum components heated at 220°C was 0.78 μm. The arithmetic mean roughness Ra of the aluminum components without the surface hydroxide process (S14) was 0.39 μm. This confirms that the surface roughness (arithmetic mean roughness Ra) of the aluminum components increases with increasing steam treatment heating temperature. Furthermore, it was confirmed that the surface roughness of the aluminum components increases when the steam treatment heating temperature is above 140°C.

[0096] [Confirmation of the surface condition of aluminum components under varying processing time]

[0097] use Figures 3-5 The sandblasting apparatus shown performs the sandblasting process (S12). The aluminum component uses aluminum sheet (JIS: A5052). During sandblasting, abrasive material of alumina with a center particle size of 106 μm to 125 μm is used. The sandblasting pressure is set to 1.0 MPa. After the sandblasting process, the surface is observed using a field emission scanning electron microscope (FE-SEM).

[0098] Next, the surface hydroxide process (S14) is performed. 10 ml of pure water is added to an autoclave, and a sandblasted aluminum plate is placed inside. Steam treatment is then performed at a heating temperature of 180°C. The treatment times are 3 hours, 6 hours, and 24 hours. It should be noted that the pressure inside the autoclave is 1.0 MPa. The surface is then observed using a field emission scanning electron microscope (FE-SEM).

[0099] Figure 14 The results of surface observation of aluminum components. Figure 14 (A) shows the surface observation results of the aluminum plate after the sandblasting process (S12). Figure 14 (B) is to Figure 14 (A) Surface observation results of the magnified aluminum plate. Figure 14 (C) shows the surface observation results of the aluminum plate 3 hours after the surface hydroxide process (S14). Figure 14 (D) is to Figure 14 (C) Surface observation results of the magnified aluminum plate. Figure 14 (E) shows the surface observation results of the aluminum plate 6 hours after the surface hydroxide process (S14). Figure 14 (F) is to Figure 14 (E) Surface observation results of the aluminum plate after magnification. Figure 14(G) represents the surface observation results of the aluminum plate 24 hours after the surface hydroxide process (S14). Figure 14 (H) is to Figure 14 (G) Surface observation results of the magnified aluminum plate.

[0100] It can be confirmed that, such as Figure 14 As shown in (A) and (B), the surface 2a of the aluminum component 2 after the sandblasting process (S12) has an uneven surface with sharp protrusions. In contrast, it can be confirmed that, as Figure 14 As shown in (C) to (H), the surface 2a of the aluminum component 2 becomes smooth overall after the surface hydroxide process (S14). Furthermore, compared... Figure 14 (C), (E), (G) and (D), (F), (H) confirm that there are fine protrusions of 50 nm to 1000 nm on the surface of the aluminum plate after the surface hydroxide process (S14).

[0101] Figure 15 The crystal structure analysis results of the surface of the aluminum component (X-ray diffraction measurement). Figure 15 In the diagram, the vertical axis represents the intensity of the diffracted X-rays, and the horizontal axis represents the diffraction angle. For example... Figure 15 As shown, X-ray diffraction analysis of the aluminum component to determine its crystal structure revealed diffraction peaks for aluminum (Al), basic alumina (AlO(OH)), and magnesium silicide (Mg₂Si). This clearly indicates that the surface of the aluminum component contains aluminum, basic alumina, and magnesium silicide. Furthermore, the longer the processing time, the more pronounced the diffraction peaks of basic alumina became. Therefore, it can be confirmed that longer processing time leads to greater growth of basic alumina.

[0102] [Confirmation of surface roughness of aluminum components under varying processing time]

[0103] Aluminum components are made of aluminum sheet (JIS: A5052). A surface hydroxide treatment process (S14) is performed on the aluminum components. As part of the surface hydroxide treatment (S14), 10 ml of pure water is added to an autoclave, and the sandblasted aluminum sheet is placed inside. The autoclave is then subjected to steam treatment at a temperature of 180°C. The steam treatment times are 2 hours, 24 hours, and 36 hours, respectively. It should be noted that the pressure inside the autoclave is 1.0 MPa.

[0104] The results showed that the arithmetic mean roughness Ra of the aluminum component was 0.40 μm when the processing time was 2 hours, 0.56 μm when the processing time was 24 hours, and 0.59 μm when the processing time was 36 hours. The arithmetic mean roughness Ra of the aluminum component without the surface hydroxide process (S14) was 0.39 μm.

[0105] This confirms that the surface roughness (arithmetic mean roughness Ra) of the aluminum component increases with longer steam treatment time. Furthermore, it is confirmed that the surface roughness of the aluminum component increases when the steam treatment time is more than 2 hours. Moreover, by comparing the results for a treatment time of 24 hours with those for 36 hours, it is confirmed that if the treatment time exceeds 24 hours, the rate of increase in the surface roughness (arithmetic mean roughness Ra) of the aluminum component slows down. Therefore, it is confirmed that steam treatment for less than 24 hours can effectively increase the surface roughness of the aluminum component.

[0106] [Confirmation of shear strength]

[0107] Prepare Examples 1-7 and Comparative Examples 1-6 to confirm shear strength.

[0108] [Examples 1-7]

[0109] In Example 1, using Figures 3-5 The sandblasting process is performed using the sandblasting apparatus shown (S12). The aluminum component uses an aluminum sheet (JIS: A5052). A surface hydroxide treatment process is then performed (S14). 10 ml of pure water is added to an autoclave, and the sandblasted aluminum sheet is placed inside. A steam treatment is then performed with the heating temperature set to 180°C and the treatment time set to 2 hours. Next, a joining process is performed (S16). Figure 6 and Figure 7 The mold 20 shown bonds the aluminum component 2 to the resin component 3. The resin component 3 is made of PPS (polyphenylene sulfide) resin. The resin component 3 is configured with dimensions of 10mm x 45mm x 3.0mm (length x width x thickness). During injection molding (when the mold is closed), the mold temperature is set to 220°C, the holding pressure is set to 5MPa, and the holding time is set to 300 seconds. The overlap between the aluminum component 2 and the resin component 3 is set to 5mm.

[0110] In Example 2, the sandblasting process (S12) and the bonding process (S16) are the same as in Example 1. In the surface hydroxide process (S14) of Example 2, a steam treatment with a treatment time of 3 hours and other conditions the same as in Example 1 is performed.

[0111] In Example 3, the sandblasting process (S12) and the bonding process (S16) are the same as in Example 1. In the surface hydroxide process (S14) of Example 3, a steam treatment with a treatment time of 6 hours and other conditions the same as in Example 1 is performed.

[0112] In Example 4, the sandblasting process (S12) and the bonding process (S16) are the same as in Example 1. In the surface hydroxide process (S14) of Example 4, a steam treatment with a treatment time of 24 hours and other conditions the same as in Example 1 is performed.

[0113] In Example 5, an aluminum plate (JIS: A5052) that underwent sandblasting (S12) and the same surface hydroxide treatment (S14) as in Example 3 was used as the aluminum component. In the sandblasting process, an alumina-based blasting material with a particle size of 106 μm to 125 μm was used. The sandblasting pressure was set to 0.4 MPa. At this time, the arithmetic mean slope of the aluminum component's surface was less than 0.17. The joining process (S16) was the same as in Example 1.

[0114] In Example 6, the sandblasting process (S12) and the bonding process (S16) are the same as in Example 1. In the surface hydroxide process (S14) of Example 6, steam treatment is performed with the heating temperature set to 140°C and other conditions the same as in Example 3.

[0115] In Example 7, the sandblasting process (S12) and the bonding process (S16) are the same as in Example 1. In the surface hydroxide process (S14) of Example 7, steam treatment is performed with the heating temperature set to 220°C and other conditions the same as in Example 3.

[0116] [Comparative Examples 1-6]

[0117] In Comparative Example 1, an aluminum plate (JIS: A5052) without sandblasting (S12) and surface hydroxideing (S14) was used as the aluminum component. The component formed by bonding this aluminum component with PPS resin is used as Comparative Example 1.

[0118] In Comparative Example 2, an aluminum plate (JIS: A5052) that underwent the same sandblasting process (S12) as in Example 1 but without the surface hydroxide process (S14) was used as the aluminum component. The joining process (S16) was the same as in Example 1.

[0119] In Comparative Example 3, an aluminum plate (JIS: A5052) that underwent the same sandblasting process (S12) as in Example 5 but without the surface hydroxide process (S14) was used as the aluminum component. The joining process (S16) was the same as in Example 1.

[0120] In Comparative Example 4, an aluminum plate (JIS: A5052) that had undergone a surface hydroxide process (S14) but not sandblasting (S12) was used as the aluminum component. In the surface hydroxide process (S14), a steam treatment was performed with the heating temperature set to 140°C and other conditions the same as in Example 4. The joining process (S16) was the same as in Example 1.

[0121] In Comparative Example 5, an aluminum plate (JIS: A5052) that had not undergone sandblasting (S12) but had undergone the same surface hydroxide process (S14) as in Example 4 was used as the aluminum component. The joining process (S16) was the same as in Example 1.

[0122] In Comparative Example 6, an aluminum plate (JIS: A5052) that had undergone a surface hydroxide process (S14) but not sandblasting (S12) was used as the aluminum component. In the surface hydroxide process (S14), a steam treatment was performed with the heating temperature set to 220°C and other conditions the same as in Example 4. The joining process (S16) was the same as in Example 1.

[0123] [Joint Strength Evaluation]

[0124] The shear strength of Examples 1-7 and Comparative Examples 1-6, prepared under the above conditions, was determined. The evaluation apparatus was used to perform the tests according to the test method of ISO 19095. Figure 16 The results are for the processing conditions and shear strength involved in the examples. For example... Figure 16 As shown, the shear strength of Example 1 was 21 MPa, the shear strength of Example 2 was 30 MPa, the shear strength of Example 3 was 38 MPa, the shear strength of Example 4 was 26 MPa, the shear strength of Example 5 was 13 MPa, the shear strength of Example 6 was 30 MPa, and the shear strength of Example 7 was 35 MPa. The shear strength of Comparative Example 1 was 1 MPa, the shear strength of Comparative Example 2 was 15 MPa, the shear strength of Comparative Example 3 was 11 MPa, the shear strength of Comparative Example 4 was 7.2 MPa, the shear strength of Comparative Example 5 was 9.9 MPa, and the shear strength of Comparative Example 6 was 3.9 MPa.

[0125] Comparative Examples 1-4 and Comparative Examples 2 and 3 confirm that by performing the sandblasting process (S12) and the surface hydroxide process (S14), the shear strength is significantly improved compared to the case where only the sandblasting process (S12) is performed. Furthermore, comparative Examples 4 and Comparative Examples 4-6 confirm that by performing the sandblasting process (S12) and the surface hydroxide process (S14), the shear strength is significantly improved compared to the case where only the surface hydroxide process (S14) is performed.

[0126] It should be noted that, comparing Comparative Examples 1 and 2 and 3, it can be confirmed that by performing only the sandblasting process (S12), the shear strength is slightly improved compared to the cases where neither the sandblasting process (S12) nor the surface hydroxide process (S14) is performed. Furthermore, comparing Comparative Examples 1 and 4-6, it can be confirmed that by performing only the surface hydroxide process (S14), the shear strength is slightly improved compared to the cases where neither the sandblasting process (S12) nor the surface hydroxide process (S14) is performed.

[0127] Therefore, it can be confirmed that by combining the sandblasting process (S12) and the surface hydroxide process (S14), the shear strength improvement effect can be achieved in both the case of performing only the sandblasting process (S12) and the case of performing only the surface hydroxide process (S14). Furthermore, it can be confirmed that as a synergistic effect of combining the sandblasting process (S12) and the surface hydroxide process (S14) (Example 4), a greater shear strength can be obtained than the shear strength obtained by simply adding the shear strength obtained in the case of performing only the sandblasting process (S12) (Comparative Example 2) and the shear strength obtained in the case of performing only the surface hydroxide process (S14) (Comparative Example 5).

[0128] Furthermore, by comparing Example 3 and Example 5, or by comparing Comparative Example 2 and Comparative Example 3, it can be confirmed that in the sandblasting process (S12), by performing sandblasting with the arithmetic mean slope of the aluminum component surface being in the range of 0.17 or more and 0.50 or less, the shear strength is significantly improved.

[0129] Comparing Examples 3 and 6, 7, or Comparing Comparative Examples 5 and 4, 6, it was confirmed that by setting the heating temperature in the surface hydroxide process (S14) to a range of 140°C or higher and 220°C or lower, the shear strength was improved. Furthermore, it was confirmed that by setting the heating temperature in the surface hydroxide process (S14) to around 180°C, the shear strength was significantly improved.

[0130] Comparing Example 3 with Examples 1, 2, and 4, it can be confirmed that by setting the processing time in the surface hydroxide process (S14) to a range of 2 hours or more but less than 24 hours, the shear strength is improved. Furthermore, it can be confirmed that by setting the processing time in the surface hydroxide process (S14) to around 6 hours, the shear strength is significantly improved.

[0131] As described above, within the range of heating temperature for the surface hydroxide process (S14) being 140°C or higher and 220°C or lower, the shear strength reaches its maximum value, becoming the peak value, when the heating temperature for the surface hydroxide process (S14) is 180°C. Furthermore, within the range of processing time for the surface hydroxide process (S14) being 2 hours or higher and 24 hours or lower, the shear strength reaches its maximum value, becoming the peak value, when the processing time for the surface hydroxide process (S14) is 6 hours.

[0132] When the heating temperature in the surface hydroxide process (S14) is above 140°C and below 180°C, there is a tendency for increased surface roughness and increased shear strength. This can be attributed to the fact that, after a constant processing time, a large amount of aluminum hydroxide is formed on the surface (contact layer) of the aluminum component, thus increasing the number of irregularities on the surface of the aluminum component. It can be considered that by increasing the number of irregularities formed on the surface of the aluminum component, the anchoring effect between the aluminum component and the resin component is also enhanced. Therefore, within the heating temperature range of above 140°C and below 180°C, the shear strength increases with increasing temperature.

[0133] When the heating temperature in the surface hydroxide process (S14) is above 180°C and below 220°C, the shear strength decreases relative to the tendency for increased surface roughness. This can be attributed to the fact that, after a constant processing time, the aluminum hydroxide formed on the surface of the aluminum component overlaps and increases in size, thus reducing the number of irregularities on the surface of the aluminum component. It can be assumed that because the number of irregularities formed on the surface of the aluminum component decreases, the anchoring effect between the aluminum component and the resin component also decreases. Therefore, within the heating temperature range of above 180°C and below 220°C, the shear strength decreases as the temperature increases. Therefore, it can be considered that within the heating temperature range of above 140°C and below 220°C, a peak in shear strength occurs around 180°C.

[0134] When the processing time in the surface hydroxide process (S14) is 2 hours or more but less than 6 hours, there is a tendency for increased surface roughness and shear strength. This can be attributed to the fact that as the processing time increases, a large amount of aluminum hydroxide is formed on the surface (contact layer) of the aluminum component, thus increasing the number of irregularities on the surface of the aluminum component. It can be assumed that by increasing the number of irregularities formed on the surface of the aluminum component, the anchoring effect between the aluminum component and the resin component is also enhanced. Therefore, within the range of 2 hours or more but less than 6 hours, the shear strength increases with longer processing time.

[0135] When the processing time in the surface hydroxide process (S14) is 6 hours or more but less than 24 hours, the shear strength decreases relative to the tendency for increased surface roughness. This can be attributed to the fact that after a constant processing time (here, 6 hours), the aluminum hydroxide formed on the surface of the aluminum component overlaps and increases in size, thus reducing the number of irregularities on the surface of the aluminum component. It can be assumed that the reduction in the number of irregularities formed on the surface of the aluminum component also reduces the contribution to the anchoring effect between the aluminum component and the resin component; therefore, within the range of processing time of 6 hours or more but less than 24 hours, the shear strength decreases as the processing time increases. Therefore, it can be considered that within the range of processing time of 6 hours or more but less than 24 hours, a peak in shear strength occurs around 6 hours.

[0136] [Confirmation of corrosion resistance]

[0137] Example 8 and Comparative Example 7 were prepared to confirm corrosion resistance.

[0138] [Example 8]

[0139] In Example 8, the same sandblasting process (S12), surface hydroxide process (S14), and bonding process (S16) as in Example 4 are performed to form a composite component.

[0140] [Comparative Example 7]

[0141] In Comparative Example 7, an aluminum plate (JIS: A5052) without sandblasting (S12) and surface hydroxideing (S14) was used as the aluminum component. The composite component formed by bonding this aluminum component with PPS resin was used as Comparative Example 7.

[0142] [Corrosion Resistance Evaluation]

[0143] As a test of the corrosion resistance of Examples 8 and Comparative Example 7, which were prepared under the above conditions, the current density was measured in an aqueous NaCl solution. The composite components of Example 8 and Comparative Example 7 were immersed in a 5 wt% (weight percentage) NaCl aqueous solution at room temperature, and the corrosion current density was calculated using the polarization resistance method. The results showed that the corrosion current density of the composite component of Example 8 was approximately 1 / 100 that of the composite component of Comparative Example 7. It can be considered that the water vapor treatment in the surface hydroxide process (S14) resulted in a decrease in the surface current density of the aluminum component by forming an amorphous layer with non-dynamic functions on the surface of the aluminum component.

[0144] [Hardness Confirmation]

[0145] Prepare Examples 9 and 10 and Comparative Example 8 to confirm hardness.

[0146] [Examples 9, 10]

[0147] In Example 9, using Figures 3-5 The sandblasting process (S12) is performed using the sandblasting apparatus shown. The aluminum component uses an aluminum plate (JIS: A5052). During sandblasting, an abrasive material of alumina with a center particle size of 106 μm to 125 μm is used. The sandblasting pressure is set to 1.0 MPa. At this point, the arithmetic mean slope of the aluminum component's surface is 0.17 or higher and 0.50 or lower. Next, a surface hydroxide treatment process (S14) is performed. 10 ml of pure water is added to an autoclave, and the sandblasted aluminum plate is placed inside. A steam treatment is performed with a heating temperature of 180°C and a treatment time of 30 minutes. Next, a bonding process (S16) is performed. Figure 6 and Figure 7 The mold 20 shown bonds the aluminum component 2 and the resin component 3 to form a composite component. The resin component 3 is made of PPS (polyphenylene sulfide) resin. The resin component 3 is defined as having a length, width, and thickness of 10mm × 45mm × 3.0mm. During injection molding (when the mold is closed), the mold temperature is set to 220℃, the holding pressure is set to 5MPa, and the holding time is set to 300 seconds. The overlap between the aluminum component 2 and the resin component 3 is set to 5mm.

[0148] In Example 10, the sandblasting process (S12) and the bonding process (S16) are the same as in Example 9. In the surface hydroxide process (S14) of Example 10, a steam treatment with a treatment time of 60 minutes and other conditions the same as in Example 9 is performed.

[0149] [Comparative Example 8]

[0150] In Comparative Example 8, an aluminum plate (JIS: A5052) without sandblasting (S12) and surface hydroxideing (S14) was used as the aluminum component. The composite component formed by bonding this aluminum component with PPS resin is used as Comparative Example 8.

[0151] [Hardness Evaluation]

[0152] The hardness of the composite components of Examples 9 and 10 and the composite component of Comparative Example 8, manufactured under the above conditions, was determined by a Vickers hardness test (JIS Z 2244 / ISO 6507-1). The test force was 0.05 kgf / mm². 2 . Figure 17 This is the result of the Vickers hardness test on the aluminum component. For example... Figure 17As shown, the Vickers hardness of Example 9 was 165 HV 0.05, the Vickers hardness of Example 10 was 178 HV 0.05, and the Vickers hardness of Comparative Example 8 was 80 HV 0.05. Based on these results, it can be confirmed that the Vickers hardness of each composite component of Examples 9 and 10 is approximately twice that of the composite component of Comparative Example 8. It can be considered that the water vapor treatment in the surface hydroxide process (S14) forms a precipitation layer on the surface of the aluminum component, thereby increasing the Vickers hardness of the aluminum component surface.

Claims

1. A method for manufacturing a composite component, comprising bonding an aluminum component and a resin component to form a composite component, comprising: The sandblasting process involves sandblasting the surface of the aluminum component. In the surface hydroxide process, pressure exceeding atmospheric pressure is applied to cause the surface of the sandblasted aluminum component to react with water vapor, thereby modifying the surface of the aluminum component into aluminum hydroxide. The bonding process involves directly bonding the resin component to the surface of the aluminum component modified into the aluminum hydroxide. In the surface hydroxide process, heat above 140°C and a treatment time of more than 2 hours and less than 24 hours are applied to allow the surface of the sandblasted aluminum component to react with water vapor.

2. The method for manufacturing the composite component according to claim 1, wherein, The aluminum hydroxide comprises at least one of diaspore, boehmite, pseudoboehmite, Bayerite, no trispore, trispore, and diaspore.

3. The method for manufacturing the composite component according to claim 1 or 2, wherein, The abrasive grains used in the sandblasting process have a particle size of 30μm to 710μm.

4. The method for manufacturing the composite component according to any one of claims 1 to 3, wherein, The resin component contains conductive filler and is conductive.

5. A composite component comprising: Aluminum components with uneven surfaces, and A resin component that is in direct contact with the surface of the aluminum component; The surface of the aluminum component has: A precipitated layer disposed on an aluminum base material, comprising alloying elements precipitated from the base material. An amorphous layer containing aluminum atoms and oxygen atoms is disposed on the precipitated layer. A contact layer disposed on the amorphous layer, comprising aluminum hydroxide, and in direct contact with the resin component. Furthermore, the resin component contains conductive filler and is conductive.

6. The composite component according to claim 5, wherein, The aluminum hydroxide comprises at least one of diaspore, boehmite, pseudoboehmite, Bayerite, no trispore, trispore, and diaspore.

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