Composite shaped body

Abstract

To provide a compound molding comprising metal molding, and nonmetal molding.SOLUTION: A compound molding comprises a first metal molding having rough-surfaced convexoconcave on the surface, and a first nonmetal molding (excluding a ceramic molding), where the first nonmetal molding is selected from a thermoplastic resin, a rubber, a thermoplastic elastomer, and a thermoset resin, the convexoconcave is composed of protrusions protruded from a reference surface which is a non-rough-surfaced surface (untreated surface) of the first metal molding, and concavities concaved from the reference surface and satisfies the following formula (I). (T-t1) / t2)=0.8-1.05 (I). In the formula. t1 is an initial thickness of a part to be bonded of the first metal molding, t2 is an initial thickness of a part to be bonded of the first nonmetal molding, T is a bonding part of the first metal molding and the first nonmetal molding of the compound molding, and the formula (I ) shows that t1, t2, and T have a relation of (T-t1) / t2)=1.0 or an approximation thereof.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a composite molded body composed of a metal molded body and a non-metal molded body (excluding ceramic molded bodies).

Background Art

[0002] A method for manufacturing a composite molded body composed of a metal molded body and a non-metal molded body such as resin is known. Patent Document 1 describes an invention of a method for manufacturing a composite molded body including a step of roughening the surface of a metal molded body by continuously irradiating laser light at an irradiation speed of 2000 mm / sec or more using a continuous wave laser device. This invention uses a continuous wave laser device that has conventionally been used for welding and cutting for the roughening treatment.

[0003] Patent Document 2 includes a step of forming a joint for joining a different material on the surface of the metal material by laser scanning processing of the surface of the metal material, and heating a thermoplastic protrusion provided on the different material and pressing the protrusion against the joint to weld the different material to the surface of the metal material by welding. This is an invention of a method for joining a metal surface and a different material. Regarding the laser scanning processing, since it is described as "continuous wave / Qswich Nd" in the examples, a pulsed wave laser device is used. It is described that in the joining step, various known welding methods such as ultrasonic welding, vibration welding, induction heating welding (induction welding), high-frequency welding (high-frequency welding), laser welding, thermal welding, spin welding, etc. can be applied (paragraph number 0040), and ultrasonic welding is used in the examples.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

SUMMARY OF THE INVENTION

PROBLEMS TO BE SOLVED BY THE INVENTION

[0005] An object of the present invention is to provide a composite molded body composed of a metal molded body and a non-metal molded body such as resin.

MEANS FOR SOLVING THE PROBLEMS

[0006] The present invention is a composite molded body composed of a first metal molded body having unevenness with a roughened surface and a first non-metal molded body (excluding a ceramic molded body), wherein the first non-metal molded body is selected from a thermoplastic resin, rubber, thermoplastic elastomer, and thermosetting resin, the unevenness is composed of a convex portion protruding from the reference surface and a concave portion recessed from the reference surface with the non-roughened surface (untreated surface) of the first metal molded body as the reference surface, and the composite molded body satisfies the following formula (I), and provides a composite molded body. (T - t1) / t2) = 0.8 to 1.05 (I) (In formula (I), t1 represents the initial thickness of the portion of the first metal molded body to be joined, t2 represents the initial thickness of the portion of the first non-metal molded body to be joined, T represents the thickness of the joined portion of the first metal molded body and the first non-metal molded body of the composite molded body, Formula (I) indicates that t1, t2, and T are in a relationship where (T - t1) / t2) = 1.0 or approximately therewith.)

[0007] The present invention is a method for manufacturing a composite molded body composed of a first metal molded body and a first non-metal molded body (excluding a ceramic molded body), which includes a first step of roughening the surface of the flat plate portion of the first metal molded body to form unevenness, and a second step of joining the flat plate portion of the first metal molded body and the flat plate portion of the first non-metal molded body. The unevenness formed in the first step consists of convex portions protruding from the reference surface and concave portions recessed from the reference surface, with the non-textured surface (untreated surface) of the first metal formed body as the reference surface. The second step is After electromagnetic induction heating a portion of the flat portion of the first metal formed body including the roughened unevenness, by bringing the portion of the flat portion of the first metal formed body including the roughened uneven surface into contact with the flat portion of the first non-metal formed body, the convex portions of the melted first metal formed body are caused to enter the first non-metal formed body, and the first non-metal formed body is made to enter the concave portions of the melted first metal formed body to join the first metal formed body and the first non-metal formed body in the second a step, or By electromagnetic induction heating in a state where the roughened uneven surface of the flat portion of the first metal formed body is in contact with the flat portion of the first non-metal formed body, the convex portions of the first metal formed body are caused to enter the melted first non-metal formed body, and the melted first non-metal formed body is made to enter the concave portions of the first metal formed body to join the first metal formed body and the first non-metal formed body in the second b step, and a method for manufacturing a composite formed body is provided.

[0008] Further, the present invention is a method for manufacturing a composite formed body composed of a second metal formed body and a second non-metal formed body (excluding a ceramic formed body), having a first step of roughening the surface of the second metal formed body to form unevenness, and a second step of joining the second metal formed body and the second non-metal formed body, wherein the second metal formed body is a formed body having a cylindrical portion or a formed body having a rod-shaped portion, and the second non-metal formed body is a formed body having a cylindrical portion or a formed body having a rod-shaped portion, wherein the composite formed body is joined in a state where one of the cylindrical portions of the second metal formed body and the second non-metal formed body has the other cylindrical portion or rod-shaped portion inserted therein, the unevenness formed in the first step consists of convex portions protruding from the reference surface and concave portions recessed from the reference surface, with the non-textured surface (untreated surface) of the second metal formed body as the reference surface. The second step is After electromagnetic induction heating the portion including the roughened unevenness of the cylindrical portion or the rod-shaped portion of the second metal formed body, by bringing the portion including the roughened uneven surface of the cylindrical portion or the rod-shaped portion of the second metal formed body into contact with or close to the rod-shaped portion or the cylindrical portion of the second non-metal formed body, the convex portion of the melted second metal formed body is made to penetrate into the second non-metal formed body, and the second non-metal formed body is made to penetrate into the concave portion of the melted second metal formed body to join the second metal formed body and the second non-metal formed body, or is the second a step, or By electromagnetic induction heating in a state where the roughened uneven surface of the cylindrical portion or the rod-shaped portion of the second metal formed body is in contact with or close to the surface of the rod-shaped portion or the cylindrical portion of the second non-metal formed body, the convex portion of the second metal formed body is made to penetrate into the melted second non-metal formed body, and the melted second non-metal formed body is made to penetrate into the concave portion of the second metal formed body to join the second metal formed body and the second non-metal formed body, which is the second b step, When the second step is the second a step, when the outer diameter of the surface on which the unevenness of the cylindrical portion or the rod-shaped portion of the second metal formed body is formed is d1, and the inner diameter of the cylindrical portion of the second non-metal formed body is d2, or when the inner diameter of the inner surface on which the unevenness of the cylindrical portion of the second metal formed body is formed is d1, and the outer diameter of the cylindrical portion or the rod-shaped portion of the second non-metal formed body is d2, the clearance C1 obtained from (d2 - d1) / 2 is in the range of -10 to 100 μm, When the second step is the second b step, when the outer diameter of the surface on which the unevenness of the cylindrical portion or the rod-shaped portion of the second metal formed body is formed is d1, and the inner diameter of the cylindrical portion of the second non-metal formed body is d2, or when the inner diameter of the inner surface on which the unevenness of the cylindrical portion of the second metal formed body is formed is d1, and the outer diameter of the cylindrical portion or the rod-shaped portion of the second non-metal formed body is d2, the clearance C2 obtained from (d2 - d1) / 2 is in the range of 0 to 100 μm, and a method for manufacturing a composite molded body is provided.

Effect of the Invention

[0009] The composite molded body of the present invention is a composite molded body with good dimensional accuracy.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0011] The manufacturing method of the composite body of the present invention includes a manufacturing method of joining the flat plate portions of the first metal formed body and the first non-metal formed body to each other (manufacturing method of the composite body of the first embodiment), and a manufacturing method of joining the cylindrical portion or rod-shaped portion of the second metal formed body and the rod-shaped portion or cylindrical portion of the second non-metal formed body (manufacturing method of the composite body of the second embodiment). The first metal formed body and the second metal formed body can be the same except for different shapes, and the first non-metal formed body and the second non-metal formed body can be the same except for different shapes.

[0012] <Manufacturing Method of the First Embodiment> As shown in Fig. 1, the composite body 1 obtained by the manufacturing method of the composite body according to the first embodiment of the present invention is one in which a first metal formed body 10 and a first non-metal formed body 20 are joined together. The manufacturing method of the composite body of the present invention has a first step of roughening the surface of the first metal formed body 10 to form unevenness, and a second step of joining the first metal formed body 10 and the first non-metal formed body 20.

[0013] (First step) Examples of the metal of the first metal formed body used in the first step of the present invention include iron, various stainless steels, aluminum, zinc, titanium, copper, brass, chromium-plated steel, magnesium, and alloys containing them (excluding the various stainless steels), cermets such as tungsten carbide and chromium carbide, and those subjected to surface treatments such as anodizing and plating can be used. The shape and size of the first metal formed body can be selected according to the use of the composite body, and the shape may be, for example, a plane, a corner portion between planes, a curved surface, or a combination thereof. In addition, the shape and size of the first metal formed body can be selected in relation to the shape and size of the first non-metal formed body to be combined. The first metal formed body only needs to have a flat plate portion, and the whole of the first metal formed body may be in a flat plate shape, or a part of the first metal formed body may be in a flat plate shape. The first non-metal formed body to be combined with the metal formed body only needs to have a flat plate portion, and the whole of the first non-metal formed body may be in a flat plate shape, or a part of the first non-metal formed body may be in a flat plate shape. In a preferred embodiment of the present invention, the thickness of the flat plate portions of the first metal formed body and the first non-metal formed body is 5 mm or less. In addition, the flat plate portion of the first metal formed body may be curved (convex curved surface or concave curved surface), and it can also be joined to the flat plate portion (concave curved surface or convex curved surface) of the non-metal formed body having a corresponding shape.

[0014] When roughening the surface of the first metal formed body 10 in the first step to form irregularities (irregular surface 12), as shown in FIGS. 1 and 2, with the non-roughened surface (untreated surface) 11 of the first metal formed body 10 as a reference surface, roughening is performed so that irregularities (irregular surface 12) composed of convex portions 13 protruding from the reference surface 11 and concave portions 14 recessed from the reference surface 11 are formed. Note that the reference surface 11 shown in FIG. 2 is a roughened portion, but is shown as a surface obtained by extending the reference surface (untreated surface) 11 shown in FIG. 1 to the irregular surface 12. As a method for roughening the surface of the first metal formed body 10 in the first step to form irregularities, methods such as continuous irradiation of continuous-wave laser light, irradiation of pulsed-wave laser light, various blasting processes, and etching can be applied.

[0015] When roughening the surface of the first metal formed body 10 in the first step by continuous irradiation of continuous-wave laser light to form irregularities, when using a continuous-wave laser, the energy density is 1 MW / cm 2 or more, and the irradiation speed is 2000 mm / sec or more for continuous irradiation, which is a preferred embodiment of the present invention. The above-described method of continuous irradiation of continuous-wave laser light in the first step is known and can be carried out in the same manner as the method of continuous irradiation of laser light described in Japanese Patent No. 5774246, Japanese Patent No. 5701414, Japanese Patent No. 5860190, Japanese Patent No. 5890054, Japanese Patent No. 5959689, Japanese Unexamined Patent Application Publication No. 2016-43413, Japanese Patent No. 6422701, and Japanese Patent No. 6353320.

[0016] When roughening the surface of the first metal formed body 10 in the first step by irradiation of pulsed-wave laser light to form irregularities, in addition to the method of irradiating normal pulsed-wave laser light, it can be carried out in the same manner as the method of irradiating pulsed-wave laser light described in Japanese Patent No. 5848104, Japanese Patent No. 5788836, Japanese Patent No. 5798534, Japanese Patent No. 5798535, Japanese Unexamined Patent Application Publication No. 2016-203643, Japanese Patent No. 5889775, Japanese Patent No. 5932700, and Japanese Patent No. 6055529.

[0017] In a preferred embodiment of the present invention, the convex portion 13 of the unevenness formed by the first step has a maximum average height (Hmax in FIG. 2) in the range of 30 μm to 300 μm from the reference surface (untreated surface) 11 of the first metal formed body 10, and the concave portion 14 of the unevenness has a maximum average depth (Dmax in FIG. 2) in the range of 30 μm to 300 μm from the reference surface (untreated surface) 11 of the first metal formed body 10. When the surface of the first metal formed body 10 is roughened by continuously irradiating continuous-wave laser light in the first step to form unevenness, although the surface of the first metal formed body 10 melts and unevenness is formed, when pulsed-wave laser light is irradiated, since very little metal is lost as in the case of performing etching or blasting, there is almost no change in the amount of metal on the surface of the first metal formed body 10, and the volume of the convex portion 13 and the volume of the concave portion 14 with respect to the reference surface 11 are substantially the same.

[0018] When roughening the surface of the first metal formed body 10 by continuously irradiating continuous-wave laser light to form unevenness in the first step, the laser light can be continuously irradiated to form unevenness so as to satisfy the following requirements (a) to (d). (a) Output is 4 to 500 W (b) Spot diameter is 10 to 80 μm (c) Energy density is 1 to 100 MW / cm 2 (d) Number of repetitions is 1 to 10 times

[0019] Requirement (a) The output of the laser is preferably 50 to 250 W in a preferred embodiment of the present invention, preferably 100 to 250 W in another preferred embodiment of the present invention, and preferably 150 to 220 W in still another preferred embodiment of the present invention.

[0020] Requirement (b) The spot diameter of the laser light is preferably 20 to 50 μm in a preferred embodiment of the present invention, and preferably 20 to 35 μm in another preferred embodiment of the present invention.

[0021] Requirement (c) The energy density during laser light irradiation is, in a preferred embodiment of the present invention, 10 to 80 MW / cm 2 and, in another preferred embodiment of the present invention, 20 to 50 MW / cm 2 . The energy density during laser light irradiation is obtained from the output (W) of the laser light and the laser light (spot area (cm 2 )(π·[spot diameter / 2] 2 ) by the following formula: output of laser light / spot area. Requirement (c) is calculated from requirement (a) and requirement (b), and requirement (c) is important in controlling the roughened state of the first metal formed body. Therefore, when there is a part where the numerical value of requirement (c) calculated from the numerical value range of requirement (a) and the numerical value range of requirement (b) is outside the above range, the numerical value range of the above requirement (c) takes precedence.

[0022] Requirement (d) The number of repetitions during laser light irradiation is 1 to 10 times, a preferred embodiment of the present invention is 1 to 8 times, and another preferred embodiment of the present invention is 2 to 8 times. The number of repetitions during laser light irradiation is the total number of irradiations for forming one line (groove) when irradiating the laser light linearly. When repeatedly irradiating one line, bidirectional irradiation and unidirectional irradiation can be selected. Bidirectional radiation is a method in which, when forming one line (groove), a continuous wave laser is irradiated from the first end to the second end of the line (groove), then a continuous wave laser is irradiated from the second end to the first end, and thereafter, the continuous wave laser is repeatedly irradiated in the order of the first end to the second end and the second end to the first end. Unidirectional irradiation is a method of repeatedly irradiating a continuous wave laser in one direction from the first end to the second end.

[0023] The irradiation conditions of the laser light excluding requirements (a) to (d) are as follows and are the same as the above-described known technology. The irradiation speed of the continuous-wave laser is preferably 2,000 to 20,000 mm / sec in one preferred embodiment of the present invention, 5,000 to 20,000 mm / sec in another preferred embodiment of the present invention, and 8,000 to 20,000 mm / sec in still another preferred embodiment of the present invention. When irradiating the continuous-wave laser light linearly, the interval (line interval) between adjacent irradiation lines (grooves formed by adjacent irradiations) is preferably 0.01 to 0.6 mm in one preferred embodiment of the present invention, 0.03 to 0.4 mm in another preferred embodiment of the present invention, and 0.03 to 0.15 mm in still another preferred embodiment of the present invention. The wavelength is preferably 300 to 1200 nm in one preferred embodiment of the present invention, and 500 to 1200 nm in another preferred embodiment of the present invention. The defocus distance is preferably -5 to +5 mm in one preferred embodiment of the present invention, -1 to +1 mm in another preferred embodiment of the present invention, and more preferably -0.5 to +0.1 mm in still another preferred embodiment of the present invention. The defocus distance may be set to a constant value for laser irradiation, or the laser irradiation may be performed while changing the defocus distance. For example, during laser irradiation, the defocus distance may be gradually decreased, or periodically increased or decreased.

[0024] The unevenness formed by continuously irradiating continuous-wave laser light so as to satisfy requirements (a) to (d) has an average of the maximum height differences (average maximum height difference) in the range of 30 to 200 μm, and the range of each maximum height difference serving as the basis for calculating the average maximum height difference is within the range of ±40% based on the average maximum height difference. (Measurement method of average maximum height difference) For a 20 mm × 20 mm area region (the entire area region if it is less than 20 mm × 20 mm) of the roughened uneven surface of the first metal formed body, a maximum of 10 locations are randomly selected within a 500 μm length range, and the maximum height difference of the unevenness within the maximum of 10 locations of the 500 μm length range (the sum of the maximum height Hmax which is the height of the highest convex portion 13 in FIG. 2 and the maximum depth Dmax which is the depth of the deepest concave portion 14) is measured from the cross-sectional photograph of the SEM, and the average value of the maximum height differences is obtained.

[0025] When the roughened area is less than 20 mm × 20 mm, measurement is performed on the entire roughened area. Also, when the roughened area is less than 20 mm × 20 mm and is very narrow and it is difficult to make 10 measurements, measurement is performed in the range of 1 to 9 locations. Furthermore, even when the roughened area is very large, if the roughening conditions are the same, it is considered that there is no difference in the structure of the uneven portions. Therefore, measurement may be performed on an arbitrary 20 mm × 20 mm area region (measurement area region). However, if necessary, 2 to 5 arbitrary 20 mm × 20 mm area regions (measurement area regions) can also be selected and measured.

[0026] In a preferred embodiment of the present invention, the average maximum height difference of the unevenness of the first metal formed body is in the range of 30 μm to 200 μm. Another preferred embodiment of the present invention is in the range of 40 μm to 150 μm. Still another preferred embodiment of the present invention is in the range of 60 μm to 125 μm. Still another preferred embodiment of the present invention is in the range of 70 μm to 100 μm. The range of the maximum height difference used as the basis for calculating the average maximum height difference is within the range of ±40% based on the average maximum height difference (for example, when the average maximum height difference is 100 μm, the range of the maximum height difference within the range of ±40% is 60 μm to 140 μm). A preferred embodiment of the present invention is within the range of ±35%.

[0027] Also, when roughening the surface of the first metal formed body by continuous irradiation with continuous-wave laser light in the first step to form unevenness, when irradiating the laser light, it can be irradiated so that the irradiated portion and the non-irradiated portion of the laser light alternate. The above continuous irradiation of continuous-wave laser light in the first step is known and can be carried out in the same manner as the continuous irradiation method of laser light described in JP-A-2018-144104. When the first step is a step of irradiating the laser light so that the irradiated portion and the non-irradiated portion of the laser light alternate in the same manner as the continuous irradiation method of laser light described in JP-A-2018-144104, Using a fiber laser device with a modulation device of a direct modulation method that directly converts the drive current of a laser connected to a laser power supply, adjusting the duty ratio obtained by the following formula from the ON time and OFF time of the output of the laser light, and irradiating so that irradiated and non-irradiated portions of the laser light occur alternately. Using a combination of a galvanometer mirror and a galvanometer controller, pulsing the laser light continuously oscillated from a laser oscillator by the galvanometer controller, adjusting the duty ratio obtained by the following formula from the ON time and OFF time of the output of the laser light, and irradiating so that irradiated and non-irradiated portions of the laser light occur alternately via the galvanometer mirror, and Any one of the steps of adjusting the duty ratio obtained by the following formula by mechanically chopping and pulsing and irradiating so that irradiated and non-irradiated portions of the laser light occur alternately can be carried out. Duty ratio (%) = ON time / (ON time + OFF time) × 100

[0028] (Second step) In the second step, when joining the flat plate portion of the first metal formed body and the flat plate portion of the first non-metal formed body, the following two methods of the second a step and the second b step can be applied.

[0029] The second a step is a step of electromagnetic induction heating a portion including the roughened unevenness of the flat plate portion of the first metal formed body to a high temperature state, and then bringing the portion including the roughened uneven surface of the flat plate portion of the metal formed body 10 into contact with the flat plate portion (surface 21 in FIG. 1) of the first non-metal formed body 20, so that, as shown in FIG. 3, the convex portion 13 of the first metal formed body enters into the first non-metal formed body 20, and the first non-metal formed body 20 enters into the concave portion 14 of the first metal formed body to join the first metal formed body 10 and the first non-metal formed body 020. In the second b step, the convex portions 13 of the first metal molded body are caused to penetrate into the melted first non-metal molded body 14 and the melted first non-metal molded body 20 is caused to penetrate into the concave portions 14 of the first metal molded body to join the first metal molded body 10 and the first non-metal molded body 20 by electromagnetic induction heating in a state where the roughened uneven surface of the flat plate portion of the first metal molded body 10 and the flat plate portion (surface 21 in FIG. 1) of the first non-metal molded body 20 are in contact with each other, as shown in FIG. 3. In the second step (the second a step and the second b step), when bringing the roughened uneven surface 12 of the flat plate portion of the first metal molded body 10 shown in FIG. 1 into contact with the flat plate portion (surface 21 in FIG. 1) of the first non-metal molded body 20, it is preferable to bring them into contact in a close contact state, and pressure can be applied so as to be in close contact. By applying electromagnetic induction heating in the second step (the second a step and the second b step), the first non-metal molded body 20 easily enters into the concave portions of the roughened unevenness of the flat plate portion of the first metal molded body 10. Therefore, it is preferable because the non-metal molding material closes only the vicinity of the entrance of the concave portion 14 and it is difficult for a sealed space to remain in the concave portion 14. Furthermore, by applying electromagnetic induction heating in the second step (the second a step and the second b step), it is preferable because it is difficult for burrs to be generated around the joint portion between the first metal molded body 10 and the first non-metal molded body 20.

[0030] In the composite molded body 1 obtained by the manufacturing method of the first embodiment, a preferable aspect of the present invention is that the first metal molded body 10 and the first non-metal molded body 20 satisfy the relationship of the following formula (I). (T - t1) / t2) = 0.8 to 1.05 (I) (In formula (I), t1 represents the initial thickness of the portion of the first metal molded body to be joined, t2 represents the initial thickness of the portion of the first non-metal molded body to be joined, T represents the thickness of the joint portion between the first metal molded body and the first non-metal molded body of the composite molded body.)

[0031] In the second step of formula (I), the convex portions 13 of the uneven portions on the roughened surface of the first metal molded body 10 penetrate into the molten first non-metal molded body 20, and the molten non-metal molded body 20 penetrates into the concave portions 14 of the uneven portions without gaps. Therefore, t1, t2, and T show a relationship where (T - t1) / t2) = 1.0 or a relationship approximated thereto. Another preferred aspect of the present invention is that formula (I) satisfies the relationship of (T - t1) / t2) = 0.85 to 1.00. As described above, since the metal loss on the processed surface of the first metal molded body 10 due to the treatment in the first step is very small and the relationship of the above formula (I) can be satisfied, the manufacturing method of the first embodiment is particularly suitable as a method for manufacturing a thin composite molded body. The lower limit value of the thickness of the joint portion between the first metal molded body and the first non-metal molded body is preferably 0.5 mm in one preferred aspect of the present invention, and preferably 1.0 mm in another preferred aspect of the present invention.

[0032] As shown in FIGS. 1 to 3, the composite molded body 1 obtained by the manufacturing method of the first embodiment of the present invention is in a state where the roughened uneven surface 12 (uneven surface 12 composed of convex portions 13 and concave portions 14) of the first metal molded body 10 is in contact with the surface 21 of the first non-metal molded body 20 (preferably in a closely adhered state), and is heated by electromagnetic induction. The convex portions 13 of the first metal molded body 10 are made to penetrate into the molten first non-metal molded body 20, and the molten first non-metal molded body 20 is made to penetrate into the concave portions 14 of the first metal molded body 10, whereby the first metal molded body 10 and the first non-metal molded body 20 are joined.

[0033] The manufacturing method of the first embodiment of the present invention is suitable as a manufacturing method for spectacle frames. A spectacle frame has a metal rim that supports two lenses, a metal bridge that connects two metal rims, two metal temples extended from the metal rim that supports two lenses via hinges, and a tip cell (made of synthetic resin or rubber) covering the tip of the metal temple. The manufacturing method of the first embodiment of the present invention can be applied as a method for joining a non-metallic molded body (excluding ceramics) to a part of an eyeglass frame.

[0034] A preferred example when applying the manufacturing method of the first embodiment of the present invention as a manufacturing method of an eyeglass frame is that the first metal molded body is the temple 60, and the first non-metallic molded body is the front cell portion (the part that a person hangs on the ear) 62. However, in this case, the front cell portion 62 is not the front cell covering the temple 60, but is directly joined to the temple 60. In this embodiment, after forming the uneven surface 61 by roughening treatment by continuously irradiating the portion to be joined with the front cell portion 62 of the pair of temples 60 with continuous wave laser light in the first step, the uneven surface 61 of the pair of temples and the pair of front cell portions (the first non-metallic molded body) 62 are brought into contact (preferably in a close contact state), and the eyeglass frame is manufactured by performing the treatment of the second step. When an eyeglass frame is manufactured by applying the manufacturing method of the first embodiment of the present invention, since the total thickness T of the joint portion between the thickness t1 of the temple 60 and the thickness t2 of the front cell portion 62 satisfies the relationship of the above formula (I), the facing intervals and directions of the pair of temples 60 and the pair of front cell portions 62 are the same, and there is no sense of discomfort when a person uses them. In addition, in a conventional eyeglass frame, since the front cell portion is used by hooking it on the ear, the front cell is not the metal as it is, but as described above, the front cell made of a soft synthetic resin or rubber is covered. However, in the process of continuous use for a long period of time, there is a problem that the front cell is damaged or displaced. However, such a problem does not occur in the eyeglass frame obtained by the manufacturing method of the first embodiment of the present application. In addition, when the rim, temple, etc. of the eyeglass frame are made of synthetic resin, the present invention can be applied for the purpose of reinforcement or decoration to join a metal member to a part of the synthetic resin rim that supports two lenses.

[0035] Moreover, the manufacturing method of the first embodiment of the present invention can be used as a joining method for making a part of a metal shift fork used as a part of a manual transmission (MT) of an automobile into a synthetic resin. For example, it can be used as a method for joining a synthetic resin to a portion where a metal shift fork contacts another metal member.

[0036] <Manufacturing Method of the Second Embodiment> Next, when the second metal molded body has a cylindrical portion or a rod-shaped portion and the second non-metal molded body has a rod-shaped portion or a cylindrical portion, a manufacturing method of the second embodiment in which one cylindrical portion is joined in a state where the other cylindrical portion or rod-shaped portion is inserted therein will be described. The types of metals that can be used are the same as those of the first metal molded body in the manufacturing method of the first embodiment. The second metal molded body only needs to have a cylindrical portion or a rod-shaped portion. In addition to the case where the entire second metal molded body is a cylindrical portion or a rod-shaped portion, a part thereof may be a cylindrical portion or a rod-shaped portion. The second non-metal molded body combined with the second metal molded body only needs to have a cylindrical portion or a rod-shaped portion. In addition to the case where the entire second non-metal molded body is a cylindrical portion or a rod-shaped portion, a part thereof may be a cylindrical portion or a rod-shaped portion. For a molded body having a cylindrical portion, the shape of other portions is not limited as long as it has the cylindrical portion. In addition to a pipe, there are those in which one end opening of the pipe is closed, and those in which one end opening of the pipe is closed and are integrated with another molded body on the closing surface. The molded body having a rod-shaped portion includes those having a hollow structure in which both ends of the cylindrical body are closed. As the second metal molded body, a molded body having a cylindrical portion with a thickness of 5 mm or less can be used. The cylindrical portion of the molded body having a cylindrical portion includes those with both ends open and those with one end opening closed. The outer diameter of the second metal molded body can be selected according to the application within the range where electromagnetic induction heating in the second step can be carried out. When using a rod-shaped body as the second metal formed body, those with a maximum length in the cross-sectional shape in the width direction of 5 mm or less (for example, when the cross-section is circular, those with a diameter of 5 mm or less) can be used. When the second metal formed body has a cylindrical portion or a rod-shaped portion, the cross-sectional shape in the width (or diameter) direction of the cylindrical portion and the cross-sectional shape in the width (or diameter) direction when the metal formed body is a rod-shaped body are not particularly limited, and in addition to polygons such as circular, elliptical, triangular, quadrangular, pentagonal, and hexagonal, specific shapes such as star-shaped and irregular shapes may also be used.

[0037] The manufacturing method combining the first step and the second a step will be described with reference to FIG. 6, and the manufacturing method combining the first step and the second b step will be described with reference to FIG. 7. However, FIGS. 6 and 7 use a structure in which the roughening treatment of the first step (the same roughening treatment as the manufacturing method of the first embodiment) is performed on the portion including the first end portion 10a of the metal rod 10A (the second metal formed body) to form the uneven surface 12. At this time, the convex portions of the uneven surface 12 protrude outward with respect to the surface that has not been roughened (reference surface). When the cross-sectional shape in the width direction of the metal rod 10A is circular, the diameter (d1) of the uneven surface 12 and the diameter (d0) of the reference surface have a relationship of d1>d0. The metal rod 10A may have a hollow inside. Instead of the metal rod 10A, a metal cylinder can also be used.

[0038] The second a step will be described with reference to FIG. 6. FIG. 6(a) shows a state in which a boss (the second non-metal formed body) 20A that is a joining partner of the metal rod 10A is placed on the workbench 90, and the metal rod 10A is disposed above it. The boss 20A is made of a thermoplastic resin. The boss 20A has a circular pedestal portion 21 and an annular inclined wall portion 22 protruding from the pedestal portion 21. An insertion hole 23 for the metal rod 10A is formed at the center of the annular inclined wall portion 22. The inner diameter of the insertion hole 23 is uniform, but it may have a portion with a different inner diameter in part. The metal rod 10A has its second end 10 fixed by the jig 100, and the first end 10a on the opposite side is positioned close to the annular end face 22a of the annular inclined wall portion 22 of the boss 20A. The jig 100 is capable of moving up and down from the state shown in Fig. 6(a). The inner diameter of the insertion hole 23 of the annular inclined wall portion 22 and the inner diameter of the concavo-convex surface 12 portion on the first end 10a side of the metal rod 10A are adjusted in advance. An electromagnetic induction heating device 70 for induction heating is arranged around the portion including the first end 10a of the metal rod 10A. Note that the electromagnetic induction heating device 70 is shown in a simplified manner.

[0039] By performing induction heating with the electromagnetic induction heating device 70 in the state shown in Fig. 6(a), the roughened portion (concavo-convex surface 12) of the metal rod 10A is heated. At this time, the heating can be performed to such an extent that the surface temperature of the portion including the concavo-convex surface 12 of the metal rod (or a metal cylinder may also be used) 10A is 50°C or more higher than the melting point of the thermoplastic resin constituting the boss 20A. Next, as shown in Fig. 6(b), by inserting the metal rod 10A into the insertion hole 23 of the boss 20A from the first end 10a side, the roughened portion (concavo-convex surface 12) in the high-temperature state can be surrounded by the annular inclined wall portion 22 of the boss 20A. Thereafter, since the thermoplastic resin constituting the annular inclined wall portion 22 is in a molten state due to the roughened portion (concavo-convex surface 12) in the high-temperature state, as shown in Figs. 2 and 3, the convex portions 13 of the concavo-convex surface 12 of the metal rod 10A enter into the boss 20, and the thermoplastic resin constituting the boss 20A enters into the concave portions 14 of the concavo-convex surface 12 of the metal rod 10A. In this way, a composite body in which the metal rod 10A and the boss 20A are joined can be obtained. In the insertion step of Fig. 6(b), the clearance C1 between the outer diameter (d1) of the concavo-convex surface 12 portion on the first end 10b side of the metal rod 10A and the inner diameter (d2) of the insertion hole 23 of the boss 20A can be expressed as (d2 - d1) / 2. At this time, the outer diameter (the outer diameter of the convex part) (d1) of the uneven surface 12 of the metal rod 10A and the outer diameter (reference surface) of the surface of the metal rod 10A that has not been roughened (d0) have a relationship of d1 > d0. A preferred embodiment of the present invention is (d1 - d0) / 2 = 0.01 to 0.30 mm, and another preferred embodiment of the present invention is (d1 - d0) / 2 = 0.03 to 0.20 mm. The clearance C1, in a preferred embodiment of the present invention, is -0.1 to 0.01 mm, in another preferred embodiment of the present invention, is -0.1 to 0.00 mm, and in yet another preferred embodiment of the present invention, is -0.05 to 0.00 mm. When the clearance C1 is positive, when the metal rod 10A is inserted into the insertion hole 23 of the boss 20A, the metal rod 10A and the insertion hole 23 do not contact each other and are in a state of being close with a slight gap. When the clearance C1 is negative, when the metal rod 10A is inserted into the insertion hole 23 of the boss 20A, the metal rod 10A and the insertion hole 23 are in a state of contact. When the clearance C1 is "0.00", it indicates that substantially d1 = d2. Note that since the clearance C1 is a requirement for facilitating the contact and joining of the metal rod 10A and the boss 20A, it is sufficient that at least a part of the insertion hole 23 of the metal rod 10A and the boss 20A satisfies the range of the clearance C1.

[0040] When implementing the second a embodiment shown in FIG. 6, since the uneven surface 12 on the first end portion 10a side of the metal rod 10A is in a pre-heated state (a state heated to a temperature sufficiently higher than the melting point of the thermoplastic resin constituting the boss 20A), even if d1 > d2, the insertion of the metal rod 10A into the insertion hole 23 becomes easy. Therefore, there is an advantage that the dimensional accuracy of the metal rod 10A and the boss 20A does not need to be very high and the processing operation becomes easy. However, since the metal rod 10A is brought into contact with the boss 20A in a heated state, the positioning of each may become difficult. In the second a step shown in FIG. 6, the metal molded body and the resin molded body can be interchanged, and it can be similarly implemented using a metal boss and a resin rod. When the metal formed body is made to have the same shape as the boss 20A shown in Fig. 6(b), the inner surface of the insertion hole 23 needs to be roughened. Therefore, the opening of the insertion hole 23 can be enlarged so that the roughening process can be easily performed.

[0041] The second b step will be described with reference to Fig. 7. The metal rod (second metal formed body) 10A, the boss (first non-metal formed body) 20A, the electromagnetic induction heating device 70, and the jig 100 are the same as those used in the embodiment shown in Fig. 6, and a metal cylinder can also be used instead of the metal rod. In Fig. 7(a), a boss (thermoplastic resin formed body) 20A, which is the mating part of the metal rod 10A, is placed on the workbench 90, and a roughened portion (concavo-convex surface 12) on the first end 10a side of the metal rod 10A is inserted into the insertion hole 23 of the boss 20. In Fig. 7(a), an electromagnetic induction heating device 70 is further arranged at a position surrounding the first end 10a side of the metal rod 10A and the boss 20A.

[0042] By performing induction heating with the electromagnetic induction heating device 70 in the state shown in Fig. 7(a), both the roughened portion (concavo-convex surface 12) on the first end 10a side of the metal rod 10A and the boss 20A are heated. At this time, the heating can be performed, for example, to a degree such that the surface temperature of the portion including the concavo-convex surface 12 of the metal rod 10A is 50°C or more higher than the melting point of the thermoplastic resin constituting the boss 20A. Due to this induction heating, as shown in Figs. 2 and 3, the convex portions 13 of the concavo-convex surface 12 of the metal rod 10A enter into the boss 20A, and the thermoplastic resin constituting the boss 20A enters into the concave portions 14 of the metal rod 10A. In this way, a composite formed body in which the metal rod 10A and the boss 20A are joined can be obtained. In the insertion step of inserting the metal rod 10A into the boss 20A in Fig. 7(a), the clearance C2 between the outer diameter (d1) of the concavo-convex surface 12 portion on the first end 10b side of the metal rod 10A and the inner diameter (d2) of the insertion hole 23 of the boss 20A can be expressed as (d2 - d1) / 2. At this time, the outer diameter (the outer diameter of the convex part) (d1) of the uneven surface 12 portion of the metal rod 10A and the outer diameter (reference surface) of the surface of the metal rod 10A that has not been roughened treatment (d0) have the relationship of d1 > d0. A preferred embodiment of the present invention is (d1 - d0) / 2 = 0.01 to 0.30 mm, and another preferred embodiment of the present invention is (d1 - d0) / 2 = 0.03 to 0.02 mm. For the clearance C2, a preferred embodiment of the present invention is -0.01 to 0.40 mm, another preferred embodiment of the present invention is 0.00 to 0.20 mm, and still another preferred embodiment of the present invention is 0.00 to 0.10 mm. When the clearance C1 is "+", when the metal rod 10A is inserted into the insertion hole 23 of the boss 20A, the metal rod 10A and the insertion hole 23 do not contact each other and are in a state of being close to each other with a slight gap. When the clearance C1 is "-", when the metal rod 10A is inserted into the insertion hole 23 of the boss 20A, the metal rod 10A and the insertion hole 23 are in a state of contact. When the clearance C1 is "0.00", it indicates that substantially d1 = d2. Note that since the clearance C2 is a requirement for making the metal rod 10A and the boss 20A easier to contact and easier to join, it is sufficient that at least a part of the insertion hole 23 of the metal rod 10A and the boss 20A satisfies the range of the clearance C2.

[0043] When implementing the second b embodiment shown in FIG. 7, since induction heating is performed with the metal rod 10A inserted into the insertion hole 23 of the boss 20A, positioning of the metal rod 10A and the boss 20A becomes unnecessary, but it is necessary to improve the dimensional accuracy of the metal rod 10A and the processing accuracy of the boss 20A. In the second b step shown in FIG. 7, the second metal molded body and the resin molded body can be replaced (with the second non-metal molded body), and the same can be implemented using a metal boss and a resin rod. When the second metal molded body is made to have the same shape as the boss 20A shown in FIG. 7(b), since the inside of the insertion hole 23 will be roughened, it can also be made to have a shape in which the opening of the insertion hole 23 is enlarged in diameter so that the roughening treatment can be easily performed.

[0044] Other embodiments of the composite body obtained by the manufacturing method of the present invention include those in which a metal cylindrical portion and a resin cylindrical portion are joined. As yet another embodiment, a composite body joined in a state where a metal pipe is inserted into a resin pipe and a composite body joined in a state where a resin pipe is inserted into a metal pipe are also included.

[0045] The manufacturing method of the second embodiment of the present invention is suitable as a manufacturing method of a syringe 50 as shown in FIG. 4. When applying the manufacturing method of the second embodiment of the present invention as a manufacturing method of a syringe, the second metal molded body is an injection needle, and the second non-metal molded body is a syringe body (the remainder excluding the injection needle from the syringe) made of a thermoplastic resin. In this embodiment, the portion to be joined to the syringe body 51 of the injection needle 52 is continuously irradiated with the continuous-wave laser light in the first step to form unevenness (uneven surface 52a) by roughening treatment. Thereafter, the uneven surface 52a of the injection needle 52 is inserted inside the cylindrical injection needle attachment portion 51a of the injection needle body 51, and the second step is performed in a state where the uneven surface 52a of the injection needle 52 is in contact with (preferably in close contact with) the cylindrical injection needle attachment portion 51a to manufacture the syringe 50. When the syringe 50 is manufactured by applying the manufacturing method of the second embodiment of the present invention, since the total thickness T of the joint portion between the thickness t1 of the injection needle 52 and the thickness t2 of the syringe body 51 satisfies the relationship of the above formula (I), the axial center of the injection needle 52 and the axial center of the syringe body 51 do not deviate, and further, the injection needle 52 does not come off from the syringe body 51, so the reliability of the syringe 50 can be improved.

[0046] The first non-metal molded body or the second non-metal molded body used in the second step (the first embodiment and the second embodiment) of the present invention excludes ceramics, and is preferably selected from thermoplastic resins, rubbers (vulcanized rubbers), thermoplastic elastomers, and thermosetting resins (however, prepolymers are used in the second step). The shape and size of the first non-metallic formed body or the second non-metallic formed body can be selected in relation to the shape and size of the metallic formed body to be combined according to the use of the composite formed body. When using a formed body having a flat plate portion with a thickness of 5 mm or less as the first metallic formed body or the second metallic formed body, a formed body having a flat plate portion with a thickness of 5 mm or less can also be used as the first non-metallic formed body or the second non-metallic formed body. When using a formed body having a cylindrical portion with a thickness of 5 mm or less or a rod-shaped portion with a maximum length of the cross-sectional shape in the width direction of 5 mm or less as the first metallic formed body or the second metallic formed body, a formed body having a cylindrical portion with a thickness of 5 mm or less can also be used as the first non-metallic formed body or the second non-metallic formed body.

[0047] The thermoplastic resin can be appropriately selected from known thermoplastic resins according to the use. Examples of the thermoplastic resin include polyamide resins (aliphatic polyamides such as PA6 and PA66, aromatic polyamides), polystyrene, copolymers containing styrene units such as ABS resin and AS resin, polyethylene, copolymers containing ethylene units, polypropylene, copolymers containing propylene units, other polyolefins, polyvinyl chloride, polyvinylidene chloride, polycarbonate resins, acrylic resins, methacrylic resins, polyester resins, polyacetal resins, polyphenylene sulfide resins, and the like.

[0048] The rubber can be cured by heat, radiation, etc. Examples of the rubber include ethylene-α-olefin rubbers such as ethylene-propylene copolymer (EPM), ethylene-propylene-diene terpolymer (EPDM), ethylene-octene copolymer (EOM), ethylene-butene copolymer (EBM), ethylene-octene terpolymer (EODM), and ethylene-butene terpolymer (EBDM); Ethylene / acrylic rubber (EAM), polychloroprene rubber (CR), acrylonitrile-butadiene rubber (NBR), hydrogenated NBR (HNBR), styrene-butadiene rubber (SBR), alkylated chlorosulfonated polyethylene (ACSM), epichlorohydrin (ECO), polybutadiene rubber (BR), natural rubber (including synthetic polyisoprene) (NR), chlorinated polyethylene (CPE), brominated polymethylstyrene-butene copolymer, styrene-butadiene-styrene and styrene-ethylene-butadiene-styrene block copolymers, acrylic rubber (ACM), ethylene-vinyl acetate elastomer (EVM), and silicone rubber can be used, etc.

[0049] The rubber may contain a curing agent according to the type of rubber as necessary, and in addition, various known rubber additives can be compounded. As rubber additives, a curing accelerator, an antioxidant, a silane coupling agent, a reinforcing agent, a flame retardant, an ozone deterioration inhibitor, a filler, a process oil, a plasticizer, a tackifier, a processing aid, etc. can be used.

[0050] The thermoplastic elastomer can be appropriately selected from known thermoplastic elastomers according to the application. Examples of the thermoplastic elastomer include styrenic elastomers, vinyl chloride-based elastomers, olefin-based elastomers, urethane-based elastomers, polyester-based elastomers, nitrile-based elastomers, polyamide-based elastomers, etc.

[0051] The thermosetting resin can be appropriately selected from known thermosetting resins according to the application. Examples of the thermosetting resin include, for example, urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin, polyurethane, vinyl urethane, etc.

[0052] Known fibrous fillers can be compounded into the non-metallic materials used for these non-metallic molded articles. Examples of well-known fibrous fillers include carbon fibers, inorganic fibers, metal fibers, and organic fibers. Carbon fibers are well-known, and those such as PAN-based, pitch-based, rayon-based, and lignin-based can be used. Examples of inorganic fibers include glass fibers, basalt fibers, silica fibers, silica-alumina fibers, zirconia fibers, boron nitride fibers, and silicon nitride fibers. Examples of metal fibers include fibers made of stainless steel, aluminum, copper, etc. Examples of organic fibers include synthetic fibers such as polyamide fibers (fully aromatic polyamide fibers, semi-aromatic polyamide fibers where either diamine or dicarboxylic acid is an aromatic compound, aliphatic polyamide fibers), polyvinyl alcohol fibers, acrylic fibers, polyolefin fibers, polyoxymethylene fibers, polytetrafluoroethylene fibers, polyester fibers (including fully aromatic polyester fibers), polyphenylene sulfide fibers, polyimide fibers, and liquid crystal polyester fibers, natural fibers (such as cellulose-based fibers), and regenerated cellulose (rayon) fibers.

[0053] These fibrous fillers can have a fiber diameter in the range of 3 to 60 μm. Among them, it is preferable to use those with a fiber diameter smaller than the opening diameter of, for example, the open pores 30 formed by roughening the joint surface 12 of the metal molded body 10. The fiber diameter is more preferably 5 to 30 μm, and even more preferably 7 to 20 μm.

[0054] In the second step (the first and second embodiments), it is preferable to perform electromagnetic induction heating at a high-frequency output of 500 to 5000 W and a frequency of 300 to 1500 kHz. The high-frequency output is more preferably 1000 to 4000 W, and even more preferably 1200 to 3000 W. The frequency is more preferably 300 to 1200 kHz, and even more preferably 400 to 1000 kHz. The oscillation time is preferably 1 to 10 seconds. The oscillation time is the time during which the magnetic field is applied and coincides with the heating time. The pressure is preferably 0.05 to 0.5 MPa, more preferably 0.1 to 0.3 MPa. Note that the pressure is the pressure applied to the metal molded body and the non-metal molded body to be joined. The load is preferably 30 to 280 N, more preferably 50 to 170 N. Note that the load is the force generated on the joint surface when pressure is applied to the metal molded body and the non-metal molded body. The holding time is preferably 1 to 30 seconds, more preferably 3 to 20 seconds. Note that the holding time is the time for holding the metal molded body and the non-metal molded body under pressure after the heating is completed, and it is the cooling time. In the second step (the first embodiment and the second embodiment), it is preferable to adjust the type of metal of the metal molded body, the type of non-metal molded body, the output (W or % with respect to the maximum output of the apparatus), the oscillation time, the pressure, and the load.

[0055] Each configuration and their combinations in each embodiment are examples, and additions, omissions, substitutions, and other changes of the configuration can be appropriately made without departing from the gist of the present invention. The present invention is not limited by the embodiments and is limited only by the scope of the claims.

Examples

[0056] (Maximum average height and maximum average depth) For a 20 mm × 20 mm area region (if less than 20 mm × 20 mm, the entire area region) of the roughened uneven surface of the first metal molded body or the second metal molded body, a maximum of 10 locations within a 500 μm length range were randomly selected, and the maximum height (Hmax in FIG. 2) and the maximum depth (Dmax in FIG. 2) of the unevenness within the maximum 10 locations of the 500 μm length range were measured from the cross-sectional photograph of the SEM, and the average values of the maximum height and the maximum depth were obtained.

[0057] The thickness (t1) of the first metal molded body and the thickness (t2) of the first non-metal molded body (resin molded body) were measured with a digital micrometer (manufactured by Mitutoyo Corporation).

[0058] (Tensile test) Using the composite body 1 shown in Fig. 1, a tensile test was conducted to evaluate the shear joint strength (S1). The tensile test was carried out in accordance with ISO19095. With the end of the metal plate (the first metal formed body) 10 fixed, the maximum load was measured until the joint surface was destroyed when pulling in the length direction of the metal plate 10 and the resin plate (the first non-metal formed body) 20 in Fig. 1 until the metal plate 10 and the resin plate 20 broke. The results are shown in Tables 3 and 4. <Tensile test conditions> Testing machine: AUTOGRAPH AG-X plus (50kN) manufactured by Shimadzu Corporation Tensile speed: 10 mm / min Distance between grips (chucks): 50 mm

[0059] Production Examples 1 to 3 (production examples corresponding to the first step of the production method of the first embodiment of the present invention) Using the following laser device, continuous wave laser light was continuously irradiated on the roughened area of the metal plate (the first metal formed body) of each example under the conditions shown in Table 1 to roughen it and form irregularities. On the surface of the metal plate, irregularities with a complex structure as shown in Fig. 2 were formed. (Laser device) Oscillator: IPG-Yb fiber; YLR-300-AC, fb diameter: 13 μm, 1069 nm Galvanometer mirror: OPTICEL D30L-CL + SQUIREEL16 (manufactured by ARGES) Condensing system 1: fc = 80 mm / fθ = 163 mm Measuring instrument: KEYENCE one-shot 3D shape measuring instrument VR-3200

[0060]

Table 1

[0061] Production Examples 4 to 6 (production examples corresponding to the first step of the production method of the first embodiment of the present invention) For two aluminum plates (A5025) (the first metal formed body) (100 mm in length, 25 mm in width, 3 mm in thickness) for each example, using the same laser device as in Production Examples 1 to 3, laser light was continuously irradiated on the roughened area (25 mm × 12.5 mm) under the conditions shown in Table 2 to roughen it and form irregularities. On the surface of the aluminum plate, irregularities with a complex structure as shown in Figure 2 were formed.

[0062]

Table 2

[0063] Production Example 7 (Comparative Production Example) Instead of continuously irradiating the continuous-wave laser light of Production Example 1, the following device was used to irradiate pulsed-wave laser light to roughen the first metal formed body (A5052). (Pulsed-wave laser device) Oscillator: IPG-Yb fiber: YLP-1-50-30-30-RA Output: 100% Frequency: 30 kHz Galvanometer mirror: LXD30 + HurrySCAN10 of SCANLAB Beam expander 2 times / fθ = 100 mm

[0064] The irradiation method and irradiation conditions are as follows. After forming a groove by linearly irradiating pulsed-wave laser light for 150 μm, irradiation was similarly performed in the opposite direction at an interval of 0.028 mm (the center-to-center distance of adjacent grooves), and one irradiation consisting of repeating this 5 times was defined as one cycle. Further, the same irradiation was repeated 5 times to form a square hole with a maximum depth of 340 μm. Further, the same irradiation was repeated to form a plurality of square holes with an interval of 150 μm between adjacent square holes. The maximum average height was 10 μm and the maximum average depth was 340 μm. When the pulsed-wave laser light is irradiated in this way, compared with Production Examples 1 to 6 in which continuous-wave laser light was continuously irradiated, the height of the convex portion is very small compared to the depth of the concave portion. Instead of unevenness, a state in which a large number of holes were substantially formed. This is because the aluminum on the surface of the metal molded body (A5052) was volatilized and lost due to the irradiation of the pulsed-wave laser light, so that no convex portion was formed and mainly holes were formed.

[0065] (Irradiation conditions) Irradiation speed: 250 mm / sec Energy density: 1258 MW / cm 2 Output: 30 W Spot diameter: 45 μm Number of repetitions (number of irradiations repeated to form one groove): 5 times Wavelength: 1069 nm Pulse width: 50 nsec Frequency: 30 kHz

[0066] Examples 1 to 4, Comparative Examples 1 to 7 The composite molded body shown in FIG. 1 was manufactured by the first step shown in Tables 3 and 4 and the second step using an electromagnetic induction heating device (manufactured by Seiden Electric Industry Co., Ltd.). The metal plate 10 has a thickness (t1) shown in Tables 3 and 4, a width of 10 mm, and a length of 45 mm. The non-metal plate (resin plate) 20 has the same shape and dimensions as the metal plate 10 except for the thickness (t2) shown in Tables 3 and 4 (LGF is an abbreviation for long glass fiber). The metal plate 10 and the resin plate 20 were brought into contact with each other, and electromagnetic induction heating was carried out while applying the pressure (load) shown in Tables 3 and 4 for the holding time shown in Tables 3 and 4. The output can be adjusted in four steps of dials 1 to 4, and dial 4 is the maximum output. (Electromagnetic induction heating device) Model: UH-2.5K Output (W): 2500 (maximum value) Oscillation frequency (kHz): 900 (maximum value) Oscillator configuration: Vacuum tube

[0067]

Table 3

[0068] In Examples 1 and 2, the metal plate and the resin plate were joined, and there was almost no burr at the joined part (Evaluation ○). In Comparative Example 1, the metal plate and the resin plate were not joined. In Comparative Example 2, the metal plate and the resin plate were joined, but a large amount of burrs were generated at the joined part compared to Examples 1 and 2 (Evaluation ×). In Comparative Example 3, the resin plate was melted. As a result of the tensile test, in Example 1, the resin plate was broken, in Example 2, it was broken at the chuck part on the resin plate side, and in Comparative Example 2, it was broken at the joint surface.

[0069] In Comparative Example 4, by applying the step of irradiating with pulsed laser light (Production Example 7), substantially no convex portion was formed and only a concave portion was formed, so (T - t1) / t2) = 1.00. However, the resin of the resin plate did not penetrate into the concave portion, and when a load was applied, a considerable amount protruded out from the joint surface, so it could not be joined. In Comparative Example 5, by applying the step of irradiating with pulsed laser light (Production Example 7), mainly concave portions were formed (because the height of the convex portion was very small compared to the depth of the concave portion), so (T - t1) / t2) = 0.95. However, the penetration of the resin of the resin plate into the concave portion was not sufficient, and the amount of burr generation was also large (Evaluation ×), so the joining strength was also reduced. In Comparative Example 6, the height of the convex portion was higher compared to Comparative Examples 4 and 5. Therefore, the joining strength was higher compared to Comparative Example 6. However, since (T - t1) / t2) = 0.78, there was unevenness in the thickness of the joined portion of the composite, and the amount of burr generation was also quite large (Evaluation ×).

[0070]

Table 4

[0071] In Example 3, the metal plate and the resin plate were joined, and there were few burrs at the joined part, but voids were generated in the resin plate at the joined part (Evaluation ○). In Example 4, the metal plate and the resin plate were joined, and there was little burr at the joined portion (Evaluation: ○). In Comparative Example 7, the resin plate was melted (Evaluation: ×). As a result of the tensile test, in Examples 3 and 4, the specimens were fractured at the joint surface.

[0072] Production Examples 8 to 11 (Production Examples corresponding to the first step of the production method of the second embodiment of the present invention) Using the following laser device, continuous wave laser light was continuously irradiated on the roughened region of the metal bar (second metal molded body) of each example under the conditions shown in Table 5 to roughen it and form unevenness. The following laser device was used. On the surface of the metal bar, unevenness with a complex structure as shown in FIG. 2 was formed. (Laser device) Oscillator: YLR-1000-SM, fb diameter: 14 μm, 1069 nm Optical system: ARGES Rino (fc = 110 mm / fθ = 163 mm)

[0073]

Table 5

[0074] Examples 5 to 8 (Examples including the second a step (FIG. 6) of the production method of the second embodiment of the present invention) The steps shown in FIGS. 6(a) and 6(b) were carried out to obtain a composite molded body in which a metal bar (second metal molded body) and a boss (second non-metal molded body) were joined. The induction heating conditions by the same electromagnetic induction heating device as in Example 1 in the second a step were as shown in Table 6.

[0075] In the tensile test, with the end on the boss 20A side fixed, the maximum load until the joint surface was fractured when the metal bar 10A was pulled in the length direction of the metal bar 10A until the metal bar 10A and the boss 20A were fractured was measured. The results are shown in Tables 6 and 7. <Tensile test conditions> Testing machine: AUTOGRAPH AG-X plus (50 kN) manufactured by Shimadzu Corporation Tensile speed: 10 mm / min Chuck distance: 50 mm

[0076]

Table 6

[0077] Examples 9 and 10 (examples including the second b step (Fig. 7) of the manufacturing method of the second embodiment of the present invention), Comparative Example 8 By carrying out the steps shown in Figs. 7(a) and (b), a composite formed body in which a metal bar (second metal formed body) and a boss (second non-metal formed body) were joined was obtained. The induction heating conditions by the same electromagnetic induction heating device as in Example 1 in the second b step were as shown in Table 7. The tensile test was carried out in the same manner as in Examples 5 to 8.

[0078]

Table 7

Industrial Applicability

[0079] The manufacturing method of the composite formed body of the present invention can manufacture a composite formed body that can be used as a substitute for metal products for the purpose of weight reduction, etc., and can be particularly used as a manufacturing method for joining thin parts such as syringes and spectacle frames.

Explanation of Signs

[0080] 1 Composite formed body 10 First metal formed body 11 Reference plane (untreated surface) 13 Convex part 14 Concave part 20 First non-metal formed body

Claims

1. A composite molded body including a first metal molded body having a surface roughened by a continuous wave laser and a first non-metallic molded body (excluding a ceramic molded body), the first non-metallic molding is selected from the group consisting of thermoplastic resin, rubber, thermoplastic elastomer, and thermosetting resin; the projections and recesses are formed by protruding from a non-roughened surface (untreated surface) of the first metal molded body as a reference surface and recesses recessed from the reference surface, The composite molded body satisfies the relationship of the following formula (I). (T-t1) / t2)=0.8~1.05 (I) (In formula (I), t1 represents an initial thickness of a portion to be joined of the first metal molded body, t2 represents an initial thickness of a portion to be joined of the first non-metallic formed body, T represents a thickness of a joint between the first metal molded body and the first non-metallic molded body of the composite molded body, Formula (I) indicates that t1, t2, and T are related such that (T-t1) / t2)=1.0 or an approximate relationship therebetween.

2. 2. The composite molding according to claim 1, wherein the convex portions of the unevenness have a maximum average height from the reference surface in the range of 30 μm to 300 μm, and the concave portions of the unevenness have a maximum average depth from the reference surface in the range of 30 μm to 300 μm.

3. the maximum average height of the convex portions of the unevenness from the reference surface is in the range of 30 μm to 300 μm, and the maximum average depth of the concave portions of the unevenness from the reference surface is in the range of 30 μm to 300 μm, 3. The composite molded product according to claim 2, which satisfies the relationship of the following formula (I): (T-t1) / t2)=0.85~1.00 (I) (In formula (I), t1 represents an initial thickness of a portion to be joined of the first metal molded body, t2 represents an initial thickness of a portion to be joined of the first non-metallic formed body, T represents a thickness of a joint between the first metal molded body and the first non-metallic molded body of the composite molded body, Formula (I) indicates that t1, t2, and T are related such that (T-t1) / t2)=1.0 or an approximate relationship therebetween.

4. The first metal molded body and the first non-metal molded body are both molded bodies having a flat plate portion with a thickness of 5 mm or less, The composite molding described in claim 1 or 2, wherein the composite molding is joined in a state where an uneven surface of a flat plate portion of the first metal molding having a thickness of 5 mm or less is in contact with a flat plate portion of the first non-metallic molding having a thickness of 5 mm or less.

5. The composite molding according to any one of claims 1 to 4, wherein the unevenness has an average maximum height difference in the range of 30 μm to 300 μm, and the range of each maximum height difference used as the basis for calculating the average maximum height difference is within a range of ±40% based on the average maximum height difference.

6. 6. The composite molded body according to claim 1, wherein a thickness of a joint between said first metal molded body and said first non-metallic molded body is 0.5 mm or more.

7. The composite molding according to any one of claims 1 to 6, The composite molding is a temple (60) of an eyeglass frame, the first non-metallic molding is made of a thermoplastic resin and includes ear-hanging portions (62) to be attached to both ends of the temple (60) of the eyeglass frame, and the uneven surfaces (61) formed on the inner surfaces of both ends of the temple (60) of the eyeglass frame and the ear-hanging portions (62) made of a thermoplastic resin are joined in a contacting state.

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