Method of manufacturing resin-metal composite structure

Abstract

To relax stress concentration at a joint face due to external force, temperature changes, etc., without changing product shapes.SOLUTION: In a method of manufacturing a resin-metal composite structure obtained by bonding a metal member 2 and a resin member 3, when performing fine uneven roughening treatment on the metal member using a pulse laser, an R shape is applied to a corner part of a joint face between the metal member 2 and the resin member 3 to be provided with the fine uneven surface, or the whole joint face is formed into a circle or an elliptical. This makes it possible to set a joint range different from the shape of the resin member.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a method for producing a resin-metal composite structure. [Background technology]

[0002] In recent years, resin-metal composite structures formed by joining metal members and resin members have been used in various fields. Patent Document 1 discloses a method for joining resin-metal composite structures inexpensively in a dry environment without using a masking member or the like by forming fine irregularities on the surface by irradiating a pulsed laser. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2022-28587 Summary of the Invention [Problem to be solved by the invention]

[0004] In a resin-metal bonded body, the strength of the uneven shape itself is improved by making the porous layer uneven, but the contour of the resin-metal bonded interface when viewed macroscopically is not taken into consideration. Therefore, when bonding the entire interface where the resin and metal contact, if the corner shape is a shape that is likely to concentrate stress, such as a right angle, stress may concentrate at that position due to external force or temperature change. More specifically, when a rectangular metal plate surface is bonded to a rectangular resin plate surface smaller than the metal, if the outer shape of the resin is the contour of the bonded interface, stress is likely to occur at the corners of the rectangular resin due to external force or temperature change.

[0005] On the other hand, there is a demand to prevent the shape of the product constituted by the resin-metal composite structure from being changed.

[0006] The present disclosure provides a method for producing a resin-metal composite structure that alleviates the concentration of stress caused by external forces, temperature changes, etc., on bonding surfaces without changing the shape of the product. [Means for solving the problem]

[0007] The method for manufacturing a resin-metal composite structure according to the present disclosure is a method for manufacturing a resin-metal composite structure formed by joining a metal member and a resin member, and when performing a fine unevenness roughening treatment on the metal member using a pulsed laser, a rounded shape is imparted to the corners of the joining surface between the metal member and the resin member to be made finely uneven, or the entire joining surface is made into a circular or elliptical shape. This makes it possible to set a joining range that differs from the shape of the resin member. Effect of the Invention

[0008] According to the present disclosure, it is possible to provide a manufacturing method for a resin-metal composite structure that can alleviate the concentration of stress caused by external forces, temperature changes, etc. that occurs on the bonding surfaces without changing the shape of the product. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram showing an example of a configuration of a manufacturing apparatus. [Diagram 2] 1 is a diagram showing a pulsed laser irradiation range of a metal material and a state in which a resin material to be joined is placed on the metal material. FIG. [Diagram 3] 13A and 13B are diagrams illustrating examples of changes in the irradiation range of the pulse laser. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] First embodiment Hereinafter, a method for manufacturing a resin-metal composite structure according to the present embodiment will be described with reference to the drawings. Here, a manufacturing apparatus 1 is used to join a metal material (metal member) 2 and a resin material (resin member) 3. FIG. 1 is a diagram showing the configuration of the manufacturing apparatus 1.

[0011] Here, the metal material 2 and the resin material 3 will be described first. Fig. 2 shows a state in which the resin material 3 is placed on the metal material 2 in order to bond the metal material 2 and the resin material 3. As shown in Fig. 2, the metal material 2 and the resin material 3 each have a rectangular shape when viewed from above, and the resin material 3 is formed to be smaller than the metal material 2.

[0012] The metal material 2 may be, but is not limited to, aluminum, copper, titanium, iron, etc. On the other hand, the resin material 3 may be, but is not limited to, polyphenylene sulfide (PPS resin), polypropylene (PP resin), epoxy resin, etc.

[0013] As shown in FIG. 1, the manufacturing apparatus 1 includes a pulse laser oscillator 11 and a control unit 12.

[0014] The pulsed laser oscillator 11 may be a laser processing machine or a laser marker. FIG. 2 is a diagram showing an example of a range in which the pulsed laser oscillator 11 irradiates a pulsed laser to scan a joining range determined on the metal material 2, and a scanning direction when scanning the range. The pulsed laser oscillator 11 performs a fine unevenness roughening process by irradiating a joining portion of the metal material 2 with the resin material 3 with a pulsed laser. Note that this fine unevenness roughening process is performed within the outline of the joining range set on the metal material 2, as described later.

[0015] The control unit 12 controls the operation of the pulse laser oscillator 11 so that the pulse laser is irradiated within the joining area contour shown in Fig. 2. For example, the control unit 12 may control not only the position where the pulse laser is irradiated but also the intensity of the pulse laser.

[0016] Next, a procedure for joining the metal material 2 and the resin material 3 using the manufacturing apparatus 1 will be described.

[0017] Fig. 2(a) is a top view showing an area to be treated with a pulsed laser before a plate-like resin material 3, which is rectangular in top view and smaller than the metal material 2, is placed on the plate surface of the metal material 2, which is rectangular in top view, and shows the outline of the joining area and the scanning area of ​​the pulsed laser. Fig. 2(b) is a top view of the joining area in a state where the resin material 3 is placed on the upper surface of the metal material 2, and Fig. 2(c) is a side view thereof.

[0018] As shown in Figures 2(a) and 2(b), in preparation for irradiating a pulsed laser from a pulsed laser oscillator 11, a control unit 12 sets the outline of a circular joining area so that the joining area falls within a range that fits within a rectangular resin material 3 when viewed from above.

[0019] Typically, as shown in the top views of Figures 2(a) and 2(b), the control unit 12 can set the position of the circular contour 21 of the joining area so that, when a resin material 3 having a rectangular shape in top view is placed, each side 3a, which is the contour of the resin material 3 itself, is circumscribed by the circular contour 21 of the joining area. Note that the contour 21 of the joining area is shown by a dashed line in Figures 2(a) and 2(b), and the shape of the contour, i.e., the shape of the entire joining surface, is not limited to a circle in top view, but may be an ellipse. Note that the inside of the contour of the joining area is the scanning range of the pulse laser, which is the joining area of ​​the metal material 2 and the resin material 3.

[0020] Here, the control unit 12 controls the operation of the pulse laser oscillator 11 so that the metal material 2 is irradiated with a pulse laser for the region inside the outline 21 of the set welding range.

[0021] Here, the directions in which the side 2a of the rectangular metal material 2 and the side 3a of the contour of the resin material 3 extend are the X direction and the Y direction. As shown in the top views of Fig. 2(a) and Fig. 2(b), the control unit 12 moves in the X direction by irradiating the pulse laser from the pulse laser oscillator 11 at a predetermined Y direction position within the contour 21 of the joining area. Then, when the X direction scanning at the predetermined Y direction position is completed, the control unit 12 moves in the Y direction to perform scanning in the X direction. Note that the direction of scanning in the X direction by the pulse laser oscillator 11 can be changed arbitrarily, but typically, scanning can be performed by reciprocating in the X direction as shown by the arrow in Fig. 2(a).

[0022] In this manner, the control unit 12 sequentially executes irradiation of the pulsed laser by the pulsed laser oscillator 11 over the entire surface within the outline 21 of the set joining range of the metal material 2 having a concave-convex shape, forming fine concave-convex shapes. Thereafter, the resin material 3 is placed on the metal material 2, and the metal material 2 and the resin material 3 are joined together.

[0023] This allows the joining of the metal material 2 and the resin material 3 by providing an outline 21 of the joining range when joining the metal material 2 and the resin material 3 at a position different from the outline of the resin material 3 itself. At this time, by making the outline 21 of the joining range circular or elliptical, the corners 3b of the resin material 3 are no longer the joining points with the metal material 2, and it is possible to alleviate the concentration of stress caused by external forces, temperature changes, etc., that occurs at the joining points.

[0024] Further, Fig. 3(a) is an example of a case where a contour 22 of a joining area is formed in a shape different from the contours of the joining area shown in Fig. 2(a) and Fig. 2(b). In the example shown in Fig. 3(a), the shape of the resin material 3 is the same as the shape shown in Fig. 2. As shown in Fig. 3(a), the control unit 12 sets the majority of the contour 22 of the joining area to follow the side 3a of the contour of the resin material 3, and sets it to have an R-shape near the corner 3b of the resin material 3.

[0025] The control unit 12 controls the pulse laser oscillator 11 to irradiate the pulse laser within the outline 22 of the joining range thus set. In this way, the manufacturing apparatus 1 can ensure a wide joining area between the metal material 2 and the resin material 3, and can also reduce stress concentration in the vicinity of the corners 3b of the resin material 3.

[0026] Fig. 3(b) is a top view of the resin material 3 when the resin material 3 has a hollow shape, and Fig. 3(c) is a cross-sectional view taken along line AA of Fig. 3(b). As shown in Fig. 3(b), the control unit 12 can set the contour of the joining area so that the hollow portion 3c of the resin material 3 does not become the irradiation area of ​​the pulse laser.

[0027] 3(b), the control unit 12 can determine the contour of the joining area to be a doughnut shape. That is, the control unit 12 can set the area between the contour 23 of the inner joining area and the contour 24 of the outer joining area as the area to be irradiated with the pulse laser by the pulse laser oscillator 11.

[0028] As a result, in the manufacturing apparatus 1, the scanning range of the pulse laser, which is the joining range, can be set to a state in which the hollow portion 3c of the resin material 3 is avoided.

[0029] Even when the contours 23, 24 of the inner and outer joining areas are defined as shown in Figure 3(b), the contour of the joining area near the corner 3b of the resin material 3 is R-shaped, so that the concentration of stress near the corner 3b can be mitigated.

[0030] From the above, when performing the fine unevenness roughening treatment on the metal material 2 using a pulsed laser, the manufacturing apparatus 1 can impart an R shape to the corners 3b of the resin material 3 in the joining area between the metal material 2 to be made finely uneven and the resin material 3, or can make the entire joining area circular or elliptical. Therefore, the manufacturing apparatus 1 can join the metal material 2 and the resin material 3 without changing the shape of the resin material 3 from a rectangular shape when viewed from above, and can also reduce stress concentration near the corners 3b of the resin material 3.

[0031] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit of the present invention. In other words, the above description has been omitted or simplified as appropriate for the purpose of clarity, and a person skilled in the art can easily modify, add, or convert each element of the embodiment within the scope of the present invention. [Explanation of symbols]

[0032] 1 Manufacturing equipment 2 Metallic materials (metallic components) Side 2a 3 Resin materials (resin components) Side 3a 3b Corner 3c Hollow part 11 Pulse laser oscillator 12 Control section 21 Contour of joint area 22 Contour of joint area 23 Inner joint area contour 24 Outer joint area contour

Claims

[Claim 1] A method for producing a resin-metal composite structure formed by joining a metal member and a resin member, comprising the steps of: When performing a finely uneven surface roughening treatment on a metal member using a pulse laser, a corner of the joining surface between the metal member to be made finely uneven and the resin member is given an R shape, or the entire joining surface is made into a circular or elliptical shape. A method for manufacturing a resin-metal composite structure.

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