Manufacturing method of a vehicle steering hanger

Abstract

To provide a method for manufacturing a steering hanger for a vehicle which has a metal member and a resin member, and has short joint process time and long open time, on the condition that joint strength between both of the members is high.SOLUTION: A method for manufacturing an on-vehicle motor includes a pre-joint step of preparing a laminate where a metal member (2), a solid adhesive (3) containing an amorphous thermoplastic resin that is at least any one of a thermoplastic epoxy resin and a phenoxy resin as a main component, and a resin member (5) which is joined to the metal member are disposed in this order, wherein an epoxy equivalent of the amorphous thermoplastic resin is 1,600 or more, or the amorphous thermoplastic resin does not contain an epoxy group, and a fusion heat of the amorphous thermoplastic resin is 15 J / g or less.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a vehicle steering hanger provided at the front part of a vehicle body.

Background Art

[0002] A vehicle steering hanger is a member that is attached to the left and right front pillars at the front part of a vehicle, supports a steering wheel via a steering column (a steering wheel attachment member), and supports an airbag, a knee bolster, etc. via a predetermined attachment member.

[0003] For example, Patent Document 1 (Japanese Unexamined Patent Application Publication No. 2008-247062) discloses a vehicle steering hanger aimed at ensuring the rigidity of a steering hanger beam and reducing the weight of the steering hanger. In Patent Document 1, in particular, the steering hanger beam is divided into a steering attachment beam portion provided with a support portion and a vehicle body attachment beam portion attached to the front pillar in the vicinity of the support portion and at a portion closer to the front pillar. The steering attachment beam portion is formed with an open cross-section, the vehicle body attachment beam portion is formed with a closed cross-section, and the end portion of the steering attachment beam portion is inserted into the end portion of the vehicle body attachment beam portion, so that the respective end portions are overlapped and integrally connected, and the respective cross-section centers of the overlapped end portions are configured to be the same.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Generally, a vehicle steering hanger is composed of a steering hanger beam made of a metal member (aluminum alloy, iron, or stainless steel) and mounting members (such as a steering wheel mounting member) made of a resin member for attaching various components (such as a steering wheel) supported by the steering hanger beam. However, Patent Document 1 does not particularly disclose a method for joining the steering hanger beam (metal member) and each mounting member (resin member).

[0006] In recent years, in view of the increasing number of components supported by the steering hanger beam with the improvement of vehicle performance, it is desired that the steering hanger beam and each mounting member be more firmly joined.

[0007] Furthermore, in recent years, particularly in automobiles, it is preferable that a steering hanger including a joint portion between a metal member and a resin member has these two members firmly joined.

[0008] As means for firmly joining dissimilar materials such as a metal member and a resin member, a liquid-type or B-stage thermosetting epoxy resin-based adhesive and a hot melt adhesive containing a thermoplastic resin are known.

[0009] However, a thermosetting epoxy resin-based adhesive with excellent adhesiveness has a long joining process time or a short open time in either a liquid type or a B-stage form. A hot melt adhesive with a short joining process time and a long open time cannot stably obtain a high adhesive force.

[0010] In the present disclosure, the joining process time means the time from the start point when at least any one of the base materials constituting the joined body comes into contact with the joining agent to the end point when the production of the joined body is completed. For example, the joining process time includes the time required for the application step and drying step of the liquid adhesive or the placement step of the solid joining agent, and the time required to bond the base materials together (for example, to cure the adhesive layer). The shorter the joining process time, the higher the productivity of the joined body can be.

[0011] In the present disclosure, the open time means the limited time from when the joining agent is applied or placed on the base material A until the placement of the base material B is completed. Within the open time, the adhesive strength of the joining agent does not decrease, and the base material A and the base material B can be bonded together with sufficient adhesive strength. The longer the open time, the higher the degree of freedom in the manufacturing process of the joined body can be.

[0012] The present disclosure has been made in view of the above-described technical background, and its object is to provide a method for manufacturing a vehicle steering hanger that includes a metal member and a resin member, has a high joining strength between the two members, has a short joining process time, and has a long open time.

Means for Solving the Problems

[0013] The present disclosure includes the following aspects.

[0014] [1] A pre-joining step of preparing a laminate in which a metal member, a solid joining agent mainly composed of an amorphous thermoplastic resin that is at least any one of a thermoplastic epoxy resin and a phenoxy resin, and a resin member to be joined to the metal member are arranged in this order; A joining step of heating and pressurizing the laminate to melt the solid joining agent and joining the metal member and the resin member A method for manufacturing a vehicle steering hanger, including: A method for manufacturing a vehicle steering hanger, wherein the epoxy equivalent of the amorphous thermoplastic resin is 1,600 or more, or the amorphous thermoplastic resin does not contain an epoxy group and the heat of fusion of the amorphous thermoplastic resin is 15 J / g or less. [2] The method for manufacturing a vehicle steering hanger according to [1], wherein the heating and pressurization are performed under the conditions of 100 to 400 °C and 0.01 to 20 MPa. [3] The method for manufacturing a vehicle steering hanger according to [1] or [2], wherein the solid binder before melting has any shape selected from the group consisting of a film, a rod, a pellet, and a powder. [4] The method for manufacturing a vehicle steering hanger according to any one of [1] to [3], wherein the metal member is a steering hanger beam, the resin member is a plurality of mounting members for mounting each of a plurality of parts supported by the steering hanger beam, and each of the resin members is joined to the surface of the metal member. [5] The method for manufacturing a vehicle steering hanger according to any one of [1] to [4], wherein the metal member is made of an extruded aluminum material of an A6000 series alloy and has characteristics of a tensile strength of 180 MPa or more and a Young's modulus of 60 GPa or more.

Advantages of the Invention

[0015] The vehicle steering hanger of the present disclosure includes a metal member and a resin member, so that the entire vehicle steering hanger is lighter than a metal one. Further, when manufacturing the vehicle steering hanger, it is not necessary to join the metal member and the resin member by welding, so that the vehicle steering hanger can be easily manufactured. Further, according to the present disclosure, it is possible to provide a method for manufacturing a vehicle steering hanger that includes a metal member and a resin member, has a high bonding strength between both members, has a short bonding process time, and has a long open time.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

DETAILED DESCRIPTION OF THE INVENTION

[0017] Next, embodiments of the present disclosure will be described below with reference to the drawings.

[0018] In the present disclosure, unless otherwise specifically specified in the text, the term "metal" is used to mean both a pure metal composed of a single metal element and an alloy in which one or more other elements are mixed with the pure metal. For example, the term "aluminum" includes pure aluminum metal and its alloys.

[0019] In the present disclosure, joining means connecting things together, and adhesion is a subordinate concept thereof, meaning joining two adherends (things to be adhered) in a joined state through an organic material (such as a curable resin or a thermoplastic resin) such as a tape or an adhesive.

[0020] FIG. 1 is a perspective view showing a vehicle to which a vehicle steering hanger (including examples of components attached to the vehicle steering hanger) according to an embodiment of the present disclosure is applied. As shown in the figure, a vehicle steering hanger 10 according to an embodiment of the present disclosure is provided between left and right front pillars (not shown) at the front of the vehicle, and is used to support a steering wheel 12, an airbag 14, and a driver center stay, a passenger center stay, a knee bolster, etc. (not shown).

[0021] FIG. 2 is a perspective view showing the vehicle steering hanger 10 shown in FIG. 1 and examples of components supported by the vehicle steering hanger 10 (specifically, the steering wheel 12 and the airbag 14). As shown in FIG. 2, the vehicle steering hanger 10 supports the steering wheel 12 and the airbag 14, and can also support other components (such as the driver center stay described above) according to the functions and performances to be realized in various vehicles.

[0022] In FIG. 2, the vehicle steering hanger 10 is composed of a cylindrical steering hanger beam 10a installed in the vehicle axle direction and a plurality of mounting members (a steering wheel mounting member 10b, an airbag mounting member 10c, a driver center stay mounting member 10d, and a passenger center stay mounting member 10e). And each mounting member 10b - 10e is joined to the steering hanger beam 10a so as to surround the steering hanger beam 10a. The steering hanger beam 10a is a metal member (for example, a member made of aluminum, iron, or stainless steel), and each mounting member 10b - 10e is a resin member. The metal member is preferably made of an A6000 series alloy aluminum extruded material and has characteristics of a tensile strength of 180 MPa or more and a Young's modulus of 60 GPa or more.

[0023] FIG. 3 is a sectional view taken along line A-A' of FIG. 2 (specifically, a view showing a section passing through the central axis of the steering hanger beam 10a and extending in the vehicle height direction), and shows the joined state of the steering hanger beam 10a and the steering wheel mounting member 10b. Although not shown, the joined states of the steering hanger beam 10a and the airbag mounting member 10c, the joined state of the steering hanger beam 10a and the driver center stay mounting member 10d, and the joined state of the steering hanger beam 10a and the passenger stay mounting member 10e are the same as the joined state of the steering hanger beam 10a and the steering wheel mounting member 10b shown in FIG. 3. In a sectional view, the mounting members 10c to 10e are joined to both sides of the steering hanger beam 10a in the vehicle height direction.

[0024] Thus, the vehicle steering hanger 10 of the present embodiment can achieve weight reduction by using members made of different materials (metal and resin) as constituent elements, as compared with the case where all are made of metal. In addition, when manufacturing the vehicle steering hanger 10, it is not necessary to weld the metal member and the resin member, so the vehicle steering hanger 10 can be easily manufactured.

[0025] Furthermore, in the vehicle steering hanger 10 of the present embodiment, by interposing a specific solid bonding agent between the steering hanger beam 10a and each of the mounting members 10b to 10e, the bonding strength between the steering hanger beam 10a and each of the mounting members 10b to 10e can be sufficiently ensured.

[0026] Next, the configuration of each member of the steering hanger 10 and its manufacturing method will be described in detail. Hereinafter, the steering hanger beam 10a corresponds to the following base material A, and each of the mounting members 10b to 10e corresponds to the following base material B.

[0027] [Manufacturing Method of Steering Hanger 10 (Joined Body)] The manufacturing method of the steering hanger of the present invention includes a metal member (hereinafter also referred to as "base material A"), a solid binder mainly composed of an amorphous thermoplastic resin which is at least one of a thermoplastic epoxy resin and a phenoxy resin, and a resin member (hereinafter also referred to as "base material B") joined to the metal member. A pre-bonding step of forming a laminate in which these are arranged in this order, and a bonding step of heating and pressurizing the laminate to melt the solid binder and bond the metal member and the frame body including the resin member. In the pre-bonding step, bonding between the base material A and the solid binder and between the base material B and the solid binder is not performed, and bonding is performed in the next bonding step. The solid binder may have tackiness, and in that case, the solid binder is temporarily fixed to the base material in the pre-bonding step.

[0028] <Pre-bonding step> In the pre-bonding step, a laminate is formed in which the base material A, a solid binder mainly composed of an amorphous thermoplastic resin which is at least one of a thermoplastic epoxy resin and a phenoxy resin, and the base material B are arranged in this order. In the laminate, neither the base material A and the solid binder nor the solid binder and the base material B are joined to each other, and they are in a state where independent members are overlapped.

[0029] The "solid" of the solid binder means solid at normal temperature, that is, having no fluidity under a non-pressurized state at 23°C. The solid binder preferably has the property of maintaining its outer shape without deformation for 30 days or more and not deteriorating further under a non-pressurized state at 23°C.

[0030] The "main component" means the component with the highest content among the resin components in the solid binder and having a content of 50% by mass or more in the resin components of the solid binder. The solid binder preferably contains 50% by mass or more of the resin component, more preferably 70% by mass or more, still more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0031] (Solid binder) The solid binder is an amorphous thermoplastic resin that is at least one of a thermoplastic epoxy resin and a phenoxy resin, and is mainly composed of an amorphous thermoplastic resin having an epoxy equivalent of 1,600 or more and a heat of fusion of 15 J / g or less.

[0032] The amorphous resin in the present disclosure is a resin that has a melting point (Tm) but does not have an endothermic peak (melting point) associated with distinct melting or has a very small endothermic peak in the measurement using a differential scanning calorimeter (DSC). The heat of fusion is calculated from the area of the endothermic peak of the DSC and the mass of the thermoplastic resin component. When an inorganic filler or the like is included in the solid binder, the heat of fusion is calculated from the mass of the resin component excluding the inorganic filler. Specifically, the amorphous thermoplastic resin in the present disclosure refers to the following. Weigh 2 to 10 mg of the sample, put it in an aluminum pan, and heat it from 23°C to 200°C or higher at 10°C / min with a DSC (DSC8231 manufactured by Rigaku Corporation) to obtain a DSC curve. Then, when the heat of fusion is calculated from the area of the endothermic peak at the time of melting obtained from the DSC curve and the weighed value, a resin with a heat of fusion of 15 J / g or less is regarded as an amorphous thermoplastic resin.

[0033] From the point of sufficiently imparting the characteristics of the amorphous thermoplastic resin to the solid binder, the content of the amorphous thermoplastic resin is preferably 60% by mass or more, more preferably 70% by mass or more, still more preferably 80% by mass or more, and most preferably 90% by mass or more of the resin components in the solid binder.

[0034] The heat of fusion is 15 J / g or less, preferably 11 J / g or less, more preferably 7 J / g or less, still more preferably 4 J / g or less, and most preferably the melting peak is below the detection limit.

[0035] The epoxy equivalent is 1,600 or more, preferably 2,000 or more, more preferably 5,000 or more, still more preferably 9,000 or more, and most preferably above the detection limit and the epoxy group is substantially not detected.

[0036] By using a solid binder mainly composed of an amorphous thermoplastic resin having an epoxy equivalent of 1,600 or more and a heat of fusion of 15 J / g or less, a rapid viscosity decrease as seen in conventional hot melt adhesives does not occur during heating, and even in a high temperature region exceeding 200°C, it does not reach a low viscosity state (0.001 to 100 Pa·s). Therefore, the solid binder does not flow out from the laminate even in a molten state, and the thickness of the adhesive layer can be stably ensured, and a high adhesive force can be stably obtained. The epoxy equivalent (the mass of the resin containing 1 mol of epoxy groups) in the present disclosure is the value of the epoxy equivalent of the thermoplastic epoxy resin or phenoxy resin component contained in the solid binder before bonding, and is a value measured by the method defined in JIS K 7236:2001 (unit "g / eq."). Specifically, the epoxy equivalent of the resin is measured using a potentiometric titrator, using cyclohexanone as a solvent, adding a brominated tetraethylammonium acetate solution to the resin, and using a 0.1 mol / L perchloric acid - acetic acid solution. For the solvent-diluted product (resin varnish), it is calculated as a numerical value in terms of solid content based on the non-volatile content. The epoxy equivalent of a mixture of two or more resins can also be calculated from the content and epoxy equivalent of each resin.

[0037] The melting point of the amorphous thermoplastic resin, which is the main component of the solid binder, is preferably 50 to 400°C, more preferably 60°C to 350°C, and even more preferably 70°C to 300°C. By having the melting point in the range of 50 to 400°C, the solid binder can be efficiently deformed and melted by heating and effectively wet and spread on the bonding surface, so that a high adhesive force can be obtained. In the present disclosure, the melting point of the amorphous thermoplastic resin means the temperature at which it substantially softens from a solid to become thermoplastic and enables melting and bonding.

[0038] In a conventional bonded body containing a thermosetting adhesive, it is difficult to disassemble the bonded body, and it is difficult to separate and recycle different materials constituting the bonded body (that is, the recyclability is poor). Further, when a thermosetting adhesive is used, it is difficult to reattach when there is a deviation at the bonding portion or the like in the manufacturing process of the bonded body, or when the adherend has a defect and needs to be replaced (that is, the repairability is poor), lacking in convenience. On the other hand, the solid binder can be softened and melted by heat and the two adherends can be easily separated, so it has excellent recyclability. Further, since the solid binder is thermoplastic, it can reversibly repeat softening, melting, and curing (solidification), and also has excellent repairability.

[0039] 《Thermoplastic Epoxy Resin》 The thermoplastic epoxy resin is preferably a polymer of (a) a bifunctional epoxy resin monomer or oligomer and (b) a bifunctional compound having the same or different two functional groups selected from the group consisting of phenolic hydroxyl group, carboxyl group, mercapto group, isocyanate group, and cyanate ester group. By using such a compound, a polymerization reaction for forming a linear polymer preferentially proceeds, and it becomes possible to form a thermoplastic epoxy resin having desired properties.

[0040] The above-mentioned (a) difunctional epoxy resin monomer or oligomer refers to an epoxy resin monomer or oligomer having two epoxy groups in the molecule. Examples of the above-mentioned (a) difunctional epoxy resin monomer or oligomer include bisphenol A type epoxy resin, bisphenol F type epoxy resin, difunctional phenol novolak type epoxy resin, bisphenol AD type epoxy resin, biphenyl type epoxy resin, difunctional naphthalene type epoxy resin, difunctional alicyclic epoxy resin, difunctional glycidyl ester type epoxy resin (such as diglycidyl phthalate, diglycidyl tetrahydrophthalate, dimer acid diglycidyl ester, etc.), difunctional glycidyl amine type epoxy resin (such as diglycidyl aniline, diglycidyl toluidine, etc.), difunctional heterocyclic epoxy resin, difunctional diaryl sulfone type epoxy resin, hydroquinone type epoxy resin (such as hydroquinone diglycidyl ether, 2,5-di-tert-butyl hydroquinone diglycidyl ether, resorcin diglycidyl ether, etc.), difunctional alkylene glycidyl ether-based compound (such as butanediol diglycidyl ether, butenediol diglycidyl ether, butynediol diglycidyl ether, etc.), difunctional glycidyl group-containing hydantoin compound (such as 1,3-diglycidyl-5,5-dialkyl hydantoin, 1-glycidyl-3-(glycidoxyalkyl)-5,5-dialkyl hydantoin, etc.), difunctional glycidyl group-containing siloxane (such as 1,3-bis(3-glycidoxypropyl)-1,1,3,3-tetramethyldisiloxane, α,β-bis(3-glycidoxypropyl)polydimethylsiloxane, etc.) and modified products thereof. Among these, bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, and biphenyl type epoxy resin are preferred from the viewpoints of reactivity and workability.

[0041] Examples of the bifunctional compound having a phenolic hydroxyl group in (b) include mononuclear aromatic dihydroxy compounds having one benzene ring such as catechol, resorcinol, and hydroquinone; bisphenol compounds such as bis(4-hydroxyphenyl)propane (bisphenol A), bis(4-hydroxyphenyl)methane (bisphenol F), and bis(4-hydroxyphenyl)ethane (bisphenol AD); compounds having a condensed ring such as dihydroxynaphthalene; bifunctional phenol compounds into which an allyl group is introduced such as diallyl resorcinol, diallyl bisphenol A, and triallyl dihydroxybiphenyl; and dibutyl bisphenol A.

[0042] Examples of the bifunctional compound having a carboxyl group in (b) include adipic acid, succinic acid, malonic acid, cyclohexanedicarboxylic acid, phthalic acid, isophthalic acid, and terephthalic acid.

[0043] Examples of the bifunctional compound having a mercapto group in (b) include ethylene glycol bisthioglycolate and ethylene glycol bisthiopropionate.

[0044] Examples of the bifunctional compound having an isocyanate group in (b) include diphenylmethane diisocyanate (MDI), isophorone diisocyanate (IPDI), hexamethylene diisocyanate (HMDI), and tolylene diisocyanate (TDI).

[0045] Examples of the bifunctional compound having a cyanate ester group in (b) include 2,2-bis(4-cyanatophenyl)propane, 1,1-bis(4-cyanatophenyl)ethane, and bis(4-cyanatophenyl)methane.

[0046] Among the above (b), a bifunctional compound having a phenolic hydroxyl group is preferable because it can form a thermoplastic polymer having suitable properties. A bifunctional compound having two phenolic hydroxyl groups and having a bisphenol structure or a biphenyl structure is preferable from the viewpoints of heat resistance and adhesiveness. Bisphenol A, bisphenol F, and bisphenol S are preferable from the viewpoints of heat resistance and cost.

[0047] When the above (a) is a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, a bisphenol S type epoxy resin, or a biphenyl type epoxy resin, and the above (b) is bisphenol A, bisphenol F, or bisphenol S, the polymer obtained by the polymerization of (a) and (b) has a para-phenylene structure and an ether bond as a main skeleton, and a main chain in which they are linked by an alkylene group, and a structure in which hydroxyl groups generated by polyaddition are arranged on the side chains. Due to the linear structure resulting from the main skeleton having a para-phenylene structure and an ether bond, the mechanical strength of the polymer after polymerization can be increased, and due to the hydroxyl groups arranged on the side chains, the adhesiveness to the substrate can be improved. As a result, while maintaining workability, a high adhesive strength equivalent to that of a thermosetting resin can be realized. Furthermore, it can be recycled and repaired by softening and melting with heat, and the recyclability and repairability, which are problems in thermosetting resins, can be improved.

[0048] 《Phenoxy Resin》 Phenoxy resin is a polyhydroxy polyether synthesized from a bisphenol compound and epichlorohydrin, and has thermoplasticity. As a method for producing phenoxy resin, a method by direct reaction of a divalent phenol compound and epichlorohydrin, and a method by addition polymerization reaction of a diglycidyl ether of a divalent phenol compound and a divalent phenol compound are known, but the phenoxy resin may be obtained by any production method. In the case of the direct reaction of a divalent phenol compound and epichlorohydrin, examples of the divalent phenol compound include phenol compounds such as bisphenol A, bisphenol F, bisphenol S, biphenyl, biphenylenediol, and fluorenediphenyl. Among these, bisphenol A, bisphenol F, and bisphenol S are preferable from the viewpoints of cost, adhesiveness, viscosity, and heat resistance. In addition to the divalent phenol compound, aliphatic glycols such as ethylene glycol, propylene glycol, and diethylene glycol may be included in the above direct reaction. These may be used alone or in combination of two or more. Phenoxy resin has a chemical structure similar to that of epoxy resin, has a para-phenylene structure and an ether bond as a main skeleton, has a main chain in which they are linked, and a structure in which hydroxyl groups are arranged in side chains.

[0049] "Thermoplastic Epoxy Resin and Phenoxy Resin" The weight average molecular weight of the thermoplastic epoxy resin and phenoxy resin is preferably 10,000 to 500,000, more preferably 18,000 to 300,000, and still more preferably 20,000 to 200,000 in terms of polystyrene conversion value measured by GPC (gel permeation chromatography). The weight average molecular weight is a standard polystyrene conversion value calculated from the elution peak position detected by GPC. When the weight average molecular weight is in the above range, the balance between thermoplasticity and heat resistance is good, so that a bonded body can be efficiently formed by melting, and the heat resistance of the bonded body can also be improved. When the weight average molecular weight is 10,000 or more, the heat resistance is excellent, and when it is 500,000 or less, the viscosity at the time of melting is low and the adhesiveness is high.

[0050] "Method for Producing Solid Adhesive" The method for producing the solid adhesive is not particularly limited. For example, it can be obtained by heating and polymerizing a monomer or oligomer of a bifunctional epoxy compound. A solvent may be added to reduce the viscosity during polymerization to make it easier to stir. When a solvent is added, its removal is necessary, and the solid adhesive may be obtained by performing drying or polymerization or both on a release film or the like.

[0051] If necessary, other additives can be blended into the solid adhesive within a range that does not inhibit the effects of the present invention. The blending amount of the additive with respect to the total amount of the amorphous thermoplastic resin is preferably 50% by volume or less, more preferably 30% by volume or less, still more preferably 20% by volume or less, and most preferably 10% by volume or less. In the present disclosure, the volume % of the additive represents the volume ratio of the additive contained before the polymerization of the monomer or oligomer of the bifunctional epoxy compound based on the volume of the total amount of the amorphous thermoplastic resin, and the volume of the additive can be obtained by dividing the mass of the contained additive by the true specific gravity of the additive.

[0052] Examples of the above additives include viscosity modifiers, inorganic fillers, organic fillers (resin powders), defoaming agents, coupling agents such as silane coupling agents, and pigments. These additives may be used alone or in combination of two or more. Examples of the viscosity modifier include reactive diluents. Examples of the inorganic filler include spherical fused silica, metal powders of metals such as iron, silica sand, talc, calcium carbonate, mica, acid clay, diatomaceous earth, kaolin, quartz, titanium oxide, silica, phenolic resin microballoons, and glass balloons.

[0053] The solid adhesive thus obtained has excellent storage stability and can be stored for a long time at room temperature because it contains little unreacted monomer or terminal epoxy group content or substantially no unreacted monomer or terminal epoxy group.

[0054] The form of the solid binder is not particularly limited, but it preferably has any shape selected from the group consisting of films, rods, pellets, and powders. In particular, at least one side of the outer shape of the solid binder is preferably 5 mm or less, more preferably 3 mm or less, still more preferably 1 mm or less, even more preferably 0.5 mm or less, and most preferably 0.3 mm or less. When the size of the solid binder is within the above range, the solid binder can be sandwiched between the base material A and the base material B and can spread efficiently on the bonding surface when heated and pressed, and a high bonding strength can be obtained.

[0055] The solid binder may have tackiness as long as it does not inhibit the adhesive strength and heat resistance. In that case, in the laminate preparation step, the solid binder can be temporarily fixed to the base material.

[0056] <Bonding step> In the bonding step, the laminate is heated and pressed to melt the solid binder, and then the temperature is lowered to solidify the solid binder, thereby bonding the base material A and the base material B.

[0057] The temperature in the heating and pressing is preferably 100 to 400 °C, more preferably 120 to 350 °C, and still more preferably 150 to 300 °C. By heating at 100 to 400 °C, the solid binder can be efficiently deformed and melted and spread effectively on the bonding surface, so that a high bonding strength can be obtained.

[0058] The pressure in the heating and pressing is preferably 0.01 to 20 MPa, more preferably 0.1 to 10 MPa, and still more preferably 0.2 to 5 MPa. When the pressure is within such a range, the solid binder can be efficiently deformed and spread effectively on the bonding surface, so that a high bonding strength can be obtained. When at least one of the base material A or the base material B contains a thermoplastic resin, by applying pressure at 0.01 to 20 MPa, the solid binder and the base material can be compatibilized to obtain a strong bonding strength.

[0059] Since the thermoplastic epoxy resin and phenoxy resin, which are the main components of the solid binder, have low cohesive force within the resin and have hydroxyl groups, they have a strong interaction with the base material and can bond dissimilar materials with higher adhesive strength than conventional crystalline hot melt adhesives.

[0060] The bonding of the base material A and the base material B utilizes the phase change (solid - liquid - solid) of the solid binder and does not involve a chemical reaction, so the bonding can be completed in a shorter time than conventional thermosetting epoxy resins.

[0061] [Steering hanger 10 (bonded body)] FIG. 4 is a schematic cross - sectional view of a state in which the metal member 2 and the resin member 5 are bonded via a solid binder, and shows, for example, the circled portion B in FIG. 3 (the bonding region between the steering hanger beam 10a and the steering wheel mounting member 10b).

[0062] In the bonded body shown in FIG. 4, the metal member 2 and the resin member 5 are bonded and integrated via an adhesive layer 3 formed by melting and then solidifying a solid binder mainly composed of an amorphous thermoplastic resin which is at least one of the thermoplastic epoxy resin and the phenoxy resin. Despite the metal member 2 and the resin member 5 being dissimilar materials, the bonded body exhibits excellent bonding strength. The bonding strength is affected by many factors such as the thickness of the adhesive layer, the molecular weight and chemical structure of the polymer constituting the adhesive, mechanical properties, viscoelastic properties, etc., in addition to the strength of the interfacial interaction acting between the adhesive layer and the base material. Therefore, although the details of the mechanism by which the bonded body of the present disclosure exhibits excellent bonding strength are not clear, it is presumed that the main factors are that the cohesive force of the amorphous thermoplastic resin constituting the adhesive layer 3 is low, there are hydroxyl groups in the resin, and chemical bonds or intermolecular forces such as hydrogen bonds and van der Waals forces are formed at the interface between the adhesive layer and the metal member 2 and at the interface between the adhesive layer and the resin member 5. However, in the bonded body, since the state or properties of the interface of the bonded body are due to a very thin chemical structure below the thickness nanometer level, analysis is difficult, and it is impossible or impractical in the current technology to express the state or properties of the interface of the bonded body of the present disclosure in a distinguishable manner from a bonded body not containing the solid binder of the present disclosure.

[0063] The steering hanger of the present disclosure in which the adhesive layer contains an amorphous thermoplastic resin is excellent in recyclability and reparability, and can be easily disassembled into the metal member 2 and the resin member 5 by heating the joined body.

[0064] <Metal member 2> Examples of the metal type of the metal member 2 include aluminum, iron, and stainless steel. Among these, aluminum is particularly preferably used from the viewpoints of light weight and ease of processing. Hereinafter, the case where aluminum is applied will be described in detail.

[0065] When aluminum is applied to the metal member 2, the type of the aluminum material of the metal member 2 is not limited. For example, the aluminum content is 50% by mass or more. Specifically, the aluminum material is preferably an A6000 series alloy (e.g., A6061, A6N01, A6063, A6082, A6110), an A5000 series alloy, an A7000 series alloy, an A3000 series alloy, etc. Further, the aluminum material is more preferably an A6N01 alloy which is a high-ductility aluminum alloy having a high energy absorption rate of deformation.

[0066] The metal member 2 is made of an aluminum extruded material of the above various alloys, and preferably has a tensile strength of 180 MPa or more and a Young's modulus of 60 GPa or more. When using an aluminum extruded material of the A6000 series alloy (for example, A6061-T6, A6082-T6, A6110-T6), a tensile strength of 300 MPa or more and a Young's modulus of 63 GPa are assumed, and when using an aluminum extruded material of the A7000 series alloy, a tensile strength of 400 MPa or more and a Young's modulus of 65 GPa are assumed. In these cases, since the metal member has high tensile strength (high strength) and high Young's modulus (high rigidity), the thickness of the steering hanger beam 10a can be reduced, and thus it contributes to the weight reduction of the vehicle steering hanger 10. The upper limit of the tensile strength is not limited, for example, it is 450 MPa. The upper limit of the Young's modulus is not limited, for example, it is 80 GPa. However, depending on the specifications, the metal member 2 may be an aluminum die-cast material, a casting material, a forging material, etc.

[0067] When the metal member 2 is made of an aluminum extruded material, the metal member 2 is preferably manufactured by the following method.

[0068] In a preferred manufacturing method of the metal member 2, a step of continuously casting a casting rod by supplying a molten aluminum material having predetermined characteristics to a continuous casting apparatus, a step of homogenizing the casting rod, a step of obtaining a billet as an extrusion processing material by cutting the casting rod to a predetermined length, a step of machining the outer diameter surface of the billet, and a step of forming an extruded material having a predetermined cross-sectional shape by hot extrusion processing of the billet are performed in this order of description. Next, the extruded material is cut to a predetermined length, and a metal member 2 made of the extruded material is obtained by performing predetermined processing such as facing and deburring on both cut end faces. In addition, if necessary, it is more preferable to perform water cooling (quenching) immediately after the above hot extrusion processing and further perform artificial aging treatment (tempering: for example, at 200 °C for 6 hours). Such heat treatment is particularly useful when strengthening the A6000 series alloy and the A7000 series alloy to high strength.

[0069] <Resin member 5> The resin member 5 preferably contains at least one selected from the group consisting of a thermoplastic resin, a thermosetting resin, and a fiber-reinforced plastic (FRP), and more preferably contains at least one selected from the group consisting of a thermoplastic resin and a fiber-reinforced plastic (FRP) from the viewpoints of adhesion, cost, and ease of molding.

[0070] Examples of the thermoplastic resin include one or more selected from the group consisting of polyolefin and its acid-modified products, polystyrene, polymethyl methacrylate, AS resin, ABS resin, thermoplastic aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonate, polyimide, polyamide, polyamideimide, polyetherimide, polyethersulfone, polyphenylene ether and its modified products, polyphenylene sulfide, polyoxymethylene, polyarylate, polyether ketone, polyether ether ketone, polyether ketone ketone, and thermoplastic epoxy resin. As the thermosetting resin, for example, one or more selected from the group consisting of epoxy resin, vinyl ester resin, phenol resin, and urethane resin can be used. The thermoplastic resin and the thermosetting resin may be used alone or in combination of two or more.

[0071] High adhesion may be obtained by performing appropriate pretreatment on the metal member 2 or the resin member 5 or both. As the pretreatment, a pretreatment for cleaning the surface of the substrate or a pretreatment for providing irregularities on the surface is preferable. The pretreatment may be only one type or two or more types may be applied. As specific methods of these pretreatments, known methods can be used.

[0072] For the metal member 2, at least one selected from the group consisting of degreasing treatment, UV ozone treatment, blasting treatment, polishing treatment, plasma treatment, and etching treatment is preferable.

[0073] For the resin member 5, at least one selected from the group consisting of degreasing treatment, UV ozone treatment, blasting treatment, polishing treatment, plasma treatment, and corona discharge treatment is preferable.

[0074] Although some embodiments of the present invention have been described, the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the present invention.

Example

[0075] Test examples and comparative test examples related to the present invention are shown below, but the present invention is not limited to the following test examples. In the following examples, the base material A and the base material B are collectively referred to as the bonding base material.

[0076] 〈Bonding base material〉 The following bonding base materials were used. 《PA66 (6,6-nylon)》 Amilan (trademark) CM3001G-30 manufactured by Toray Industries, Inc. was injection molded to obtain test pieces having a width of 10 mm, a length of 45 mm, and a thickness of 3 mm. They were used without surface treatment. 《Aluminum》 The surface of A6061-T6 was blasted to obtain test pieces having a width of 10 mm, a length of 45 mm, and a thickness of 3 mm.

[0077] 〈Weight average molecular weight, heat of fusion, and epoxy equivalent of thermoplastic epoxy resin and phenoxy resin〉 The weight average molecular weight, heat of fusion, and epoxy equivalent of the thermoplastic epoxy resin and the phenoxy resin were measured by the following procedures, respectively.

[0078] (Weight average molecular weight) The thermoplastic epoxy resin and the phenoxy resin were dissolved in tetrahydrofuran and measured under the following conditions using Prominence 501 (manufactured by Showa Science Co., Ltd., Detector: Shodex (registered trademark) RI-501 (manufactured by Showa Denko K.K.)). Column: Two LF-804 columns manufactured by Showa Denko K.K. Column temperature: 40°C Sample: 0.4 mass% tetrahydrofuran solution of resin Flow rate: 1 mL / min Eluent: Tetrahydrofuran Calibration method: Conversion using standard polystyrene

[0079] (Heat of fusion) Weigh 2 - 10 mg of thermoplastic epoxy resin and phenoxy resin, put them into an aluminum pan, and using a DSC (DSC8231 manufactured by Rigaku Corporation), heat from 23°C to 200°C at 10°C / min to obtain a DSC curve. The heat of fusion was calculated from the area of the endothermic peak during melting of the obtained DSC curve and the weighed value.

[0080] (Epoxy equivalent) The measured values obtained in accordance with JIS K 7236:2001 were converted to values as resin solids. In the case of a simple mixture without reaction, they were calculated from the respective epoxy equivalent and content.

[0081] 〈Example Test Example 1〉 (Solid adhesive P - 1) Into a reaction apparatus equipped with a stirrer, reflux condenser, gas inlet tube, and thermometer, charge 203 g (1.0 equivalent) of jER (registered trademark) 1007 (bisphenol A type epoxy resin, weight average molecular weight of about 10,000, manufactured by Mitsubishi Chemical Corporation), 12.5 g (1.0 equivalent) of bisphenol S, 2.4 g of triphenylphosphine, and 1,000 g of methyl ethyl ketone. Heat to 100°C with stirring under a nitrogen atmosphere. After visually confirming dissolution, cool to 40°C to obtain a resin composition with a solid content of about 20 mass%. Remove the solvent from the resin composition to obtain a film - shaped solid adhesive (P - 1) with a solid content of 100 mass% and a thickness of 100 μm. The weight average molecular weight was about 37,000. The epoxy equivalent was above the detection limit. No heat of fusion peak was detected by DSC. (Bonded body) A joint body of a base material A (metal member) and a base material B (resin member) shown in Table 1 was fabricated. For the open time evaluation, a solid bonding agent was placed on the aluminum base material (base material A) and left standing for 3 days, and then a joint body for open time evaluation was also fabricated in the same procedure except that the PA66 base material (base material B) was placed thereon afterwards.

[0082] The solid bonding agent P-1 cut into a size of 10×15 mm was placed on the base material A, and then immediately thereon, the base material B was placed. The overlap between these base materials was 10 mm in width and 5 mm in depth. The solid bonding agent P-1 was placed so as to cover the entire overlap region between the base materials. That is, a non-bonded laminate was prepared such that the base materials A and B did not directly touch each other and the solid bonding agent was interposed therebetween. Using a high-frequency induction welding machine (manufactured by Seiden Electric Industry Co., Ltd., oscillator UH-2.5K, press JIIP30S), metal was heated by high-frequency induction, and the test pieces were joined by heating and pressurization. The pressing force was 110 N (pressure 2.2 MPa), the oscillation frequency was 900 kHz, and the oscillation time was 6 seconds.

[0083] 〈Example Test 2〉 (Solid bonding agent P-2) Into a reaction apparatus equipped with a stirrer, a reflux condenser, a gas introduction tube, and a thermometer, 20 g of Enotate (registered trademark) YP-50S (manufactured by Nippon Steel Chemical & Material Co., Ltd., phenoxy resin, weight average molecular weight of about 50,000) and 80 g of cyclohexanone were charged, and the temperature was raised to 60 °C with stirring, and it was confirmed visually that dissolution had occurred, and then cooled to 40 °C to obtain a resin composition having a solid content of 20 mass%. The solvent was removed from the resin composition to obtain a film-like solid bonding agent (P-2) having a solid content of 100 mass% and a thickness of 100 μm. The weight average molecular weight was 50,000, and the epoxy equivalent was above the detection limit. No melting heat peak was detected by DSC. (Joint body) A joint body shown in Table 1 and a joint body for open time evaluation were fabricated in the same manner as in Example Test 1 except that P-2 was used as the solid bonding agent.

[0084] 〈Example Test 3〉 (Solid Adhesive P-3) The resin composition P-2 and the crystalline epoxy resin YSLV-80XY (manufactured by Nippon Steel Chemical & Material Co., Ltd.) were mixed at a mass ratio of 98 to 2 to obtain a solid adhesive (P-3). The weight average molecular weight was 36,000, the epoxy equivalent was 9600 g / eq, and the heat of fusion was 2 J / g. (Bonded Body) A bonded body shown in Table 1 and a bonded body for open time evaluation were produced in the same manner as in Test Example 1, except that P-3 was used as the solid adhesive.

[0085] 〈Test Example 4〉 (Solid Adhesive P-4) The resin composition P-2 and the crystalline epoxy resin YSLV-80XY (manufactured by Nippon Steel Chemical & Material Co., Ltd.) were mixed at a mass ratio of 94 to 6 to obtain a solid adhesive (P-4). The weight average molecular weight was 35,000, the epoxy equivalent was 2100 g / eq, and the heat of fusion was 4 J / g. (Bonded Body) A bonded body shown in Table 1 and a bonded body for open time evaluation were produced in the same manner as in Test Example 1, except that P-4 was used as the solid adhesive.

[0086] 〈Test Example 5〉 (Solid Adhesive P-5) The resin composition P-2 and the crystalline epoxy resin YSLV-80XY (manufactured by Nippon Steel Chemical & Material Co., Ltd.) were mixed at a mass ratio of 89 to 11 to obtain a solid adhesive (P-5). The weight average molecular weight was 33,000, the epoxy equivalent was 1745 g / eq, and the heat of fusion was 11 J / g. (Bonded Body) A bonded body shown in Table 1 and a bonded body for open time evaluation were produced in the same manner as in Test Example 1, except that P-5 was used as the solid adhesive.

[0087] 〈Test Example 6〉 (Solid Adhesive P-6) Into a reactor equipped with a stirrer, a reflux condenser, a gas inlet tube, and a thermometer, 203 g (1.0 equivalent) of jER (registered trademark) 1007 (manufactured by Mitsubishi Chemical Corporation, bisphenol A type epoxy resin, molecular weight about 4060), 12.5 g (0.6 equivalent) of bisphenol S (molecular weight 250), 2.4 g of triphenylphosphine, and 1,000 g of methyl ethyl ketone were charged, and the temperature was raised to 100 °C while stirring under a nitrogen atmosphere. After visually confirming dissolution, it was cooled to 40 °C to obtain a resin composition having a solid content of about 20% by mass. The solvent was removed from the resin composition to obtain a film-like solid adhesive (P-6) having a solid content of 100% by mass and a thickness of 100 μm. The weight average molecular weight was about 30,000, and the epoxy equivalent was above the detection limit. No melting heat peak was detected by DSC. (Bonded body) A bonded body shown in Table 1 and a bonded body for open time evaluation were produced in the same manner as in Test Example 1 except that P-6 was used as the solid adhesive.

[0088] 〈Comparative Test Example 1〉 (Solid adhesive Q-1) Two components of a thermosetting liquid epoxy adhesive E-250 (manufactured by Konishi Co., Ltd., a two-component type of bisphenol type epoxy resin and an amine curing agent) were mixed, applied to a release film, cured at 100 °C for 1 hour, then cooled, and peeled off from the release film to obtain a film-like solid adhesive (Q-1) having a thickness of 100 μm. No melting heat peak was detected by DSC. The epoxy equivalent and the weight average molecular weight could not be measured because they were insoluble in the solvent. (Bonded body) A bonded body shown in Table 1 and a bonded body for open time evaluation were produced in the same manner as in Test Example 1 except that Q-1 was used as the solid adhesive.

[0089] 〈Comparative Test Example 2〉 (Solid adhesive Q-2) An amorphous polycarbonate film (Iupilon (registered trademark) FE2000, manufactured by Mitsubishi Engineering-Plastics Corporation, thickness 100 μm) was used as the solid bonded body Q-2. No melting heat peak was detected by DSC. (Bonded body) Except for using Q-2 as the solid bonding agent, the bonded bodies shown in Table 1 and the bonded bodies for open time evaluation were produced in the same manner as in Test Example 1.

[0090] 〈Comparative Test Example 3〉 (Solid bonding agent Q-3) Crystalline epoxy resin YSLV-80XY (manufactured by Nippon Steel Chemical & Material Co., Ltd.) was used as the solid bonding agent (Q-3). The epoxy equivalent was 192 g / eq. The weight average molecular weight was 340. The heat of fusion was 70 J / g. (Bonded body) Except for using Q-3 as the solid bonding agent, the bonded bodies shown in Table 1 and the bonded bodies for open time evaluation were produced in the same manner as in Test Example 1.

[0091] 〈Comparative Test Example 4〉 (Bonded body) Two components of the thermosetting liquid epoxy adhesive E-250 (manufactured by Konishi Co., Ltd., a two-component type of bisphenol type epoxy resin and an amine curing agent) were mixed, applied to the same base materials A and B as in Test Example 1 respectively, bonded within 1 minute, and then left standing in an oven at 100 °C for 1 hour in a state fixed with clips to cure the adhesive components, and then cooled to room temperature to produce the bonded bodies shown in Table 1. Except for applying the thermosetting liquid epoxy adhesive E-250 to base materials A and B respectively and bonding after standing for 3 days, the bonded bodies for open time evaluation were also produced in the same manner as above.

[0092] 〈Comparative Test Example 5〉 Into a flask, 203 g (1.0 equivalent) of jER (registered trademark) 1007 (manufactured by Mitsubishi Chemical Corporation, bisphenol A type epoxy resin, weight average molecular weight of about 10,000), 12.5 g (1.0 equivalent) of bisphenol S, 2.4 g of triphenylphosphine, and 1,000 g of methyl ethyl ketone were charged and stirred at room temperature to obtain a liquid resin composition having a solid content of about 20% by mass. On the same substrate B as in Test Example 1, the liquid resin composition was bar-coated, dried at room temperature for 30 minutes, and then left standing in an oven at 160 °C for 2 hours to form a solid thermoplastic epoxy resin polymer coating layer with a thickness of 100 μm on the surface of substrate B. The weight average molecular weight of the coating layer was about 40,000. The epoxy equivalent was above the detection limit. No melting heat peak was detected by DSC. (Bonded body) A bonded body shown in Table 1 was prepared in the same manner as in Test Example 1, except that substrate A was directly placed on substrate B having the coating layer. For the open time evaluation, after forming a thermoplastic epoxy resin polymer coating layer on the surface of substrate B, it was left standing for 3 days and then laminated with substrate A in the same manner as above to prepare a bonded body for open time evaluation.

[0093] 〈Comparative Test Example 6〉 Into a reaction apparatus equipped with a stirrer, a reflux condenser, a gas inlet tube, and a thermometer, 20 g of Phenotole (registered trademark) YP-50S (manufactured by Nippon Steel Chemical & Material Co., Ltd., phenoxy resin, weight average molecular weight of about 50,000) and 80 g of cyclohexanone were charged, heated to 60 °C with stirring, and confirmed to be visually dissolved. After cooling to 40 °C, a liquid resin composition having a solid content of 20% by mass was obtained. On the same substrate B as in Test Example 1, the liquid resin composition was bar-coated and left standing in an oven at 70 °C for 30 minutes to form a phenoxy resin coating layer with a thickness of 100 μm on the surface of substrate B. The weight average molecular weight of the coating layer was about 50,000. The epoxy equivalent was above the detection limit. No melting heat peak was detected by DSC. (Bonded body) A laminate was prepared in the same manner as in Test Example 1, except that Substrate A was directly placed on Substrate B having the phenoxy resin coating layer. For the open time evaluation, after forming the phenoxy resin coating layer on the surface of Substrate B and allowing it to stand for 3 days, a laminate for open time evaluation was also prepared in the same manner as above, except that it was laminated with Substrate A after that.

[0094] 〈Comparative Test Example 7〉 (Laminate) A laminate shown in Table 1 and a laminate for open time evaluation were prepared in the same manner as in Test Example 1, except that a crystalline polyamide-based hot melt adhesive film NT-120 (manufactured by Nippon MatTai Co., Ltd., thickness 100 μm) was used as the solid adhesive. The heat of fusion was 60 J / g.

[0095] [Shear Adhesion Strength] After allowing the laminates obtained in Test Examples 1 to 6 and Comparative Test Examples 1 to 7 to stand at the measurement temperature (23°C or 80°C) for 30 minutes or more, in accordance with ISO 19095, a tensile shear adhesion strength test was conducted in an atmosphere of 23°C and 80°C using a tensile testing machine (Autograph "AG-X plus" (manufactured by Shimadzu Corporation); load cell 10 kN, tensile speed 10 mm / min), and the bonding strength was measured. The measurement results are shown in Table 1.

[0096] [Bonding Process Time] The bonding process time was measured as follows. Starting from the time of contact between at least one of the substrates constituting the laminate and the adhesive, and ending at the completion of the production of the laminate, the time from the start point to the end point was measured. For the heating and pressurization time, the respective heating and pressurization times of the laminates shown in Table 1 were averaged.

[0097] [Recyclability] The laminates shown in Table 1 were placed on a hot plate at 200°C and heated for 1 minute, and then judged whether they could be easily peeled off with a force of 1 N or less. If all the laminates could be peeled off, it was judged as good (OK), and if there was any that could not be peeled off, it was judged as unsuitable (NG).

[0098] [Repairability] Among the test pieces in which the bonded surface after the test at 23°C in the tensile shear strength test was broken (with a layer of the bonding solid remaining on the surface of base material A or B or both), base material A was placed on base material B, and a repair joint was obtained by creating a joint body in the same manner as in Test Example 1. The shear adhesive strength of the repair joint at 23°C was measured in the same manner as in the test method. If it was 80% or more of the shear adhesive strength in the first measurement, it was considered good (OK); if it was less than 80%, it was considered unsuitable (NG).

[0099] [Open Time Evaluation] Using the joint body for open time evaluation, the tensile shear adhesive strength test was carried out at 23°C. Compared with the test pieces prepared by the methods of the test examples and comparative test examples, if the shear adhesive strength was 80% or more, it was considered good (OK); if it was less than 80%, it was considered unsuitable (NG). A good open time evaluation (OK) means a long open time and excellent convenience.

[0100]

Table 1-1

Table 1-2

Industrial Applicability

[0101] The present invention can be used in the manufacturing method of a steering hanger.

Explanation of Signs

[0102] 2: Metal member 3: Solid bonding agent 5: Resin member 10: Vehicle steering hanger (metal member-resin member joint) 10a: Steering hanger beam 10b: Steering wheel mounting member 10c: Airbag mounting member 10d: Driver center stay mounting member 10e: Passenger center stay mounting member 12: Steering wheel 14: Airbag

Claims

1. A pre-bonding step of preparing a laminate in which a metal member, a solid bonding agent mainly composed of an amorphous thermoplastic resin which is at least one of a thermoplastic epoxy resin and a phenoxy resin, and a resin member to be bonded to the metal member are arranged in this order; A bonding step of heating and pressurizing the laminate to melt the solid bonding agent and bond the metal member and the resin member A method for manufacturing a vehicle steering hanger, comprising: The method for manufacturing a vehicle steering hanger, wherein the epoxy equivalent of the amorphous thermoplastic resin is 1,600 or more, or the amorphous thermoplastic resin does not contain an epoxy group and the heat of fusion of the amorphous thermoplastic resin is 15 J / g or less.

2. The method for manufacturing a vehicle steering hanger according to Claim 1, wherein the heating and pressurization are performed under conditions of 100 to 400°C and 0.01 to 20 MPa.

3. The method for manufacturing a vehicle steering hanger according to Claim 1 or 2, wherein the solid bonding agent before melting has any shape selected from the group consisting of a film, a rod, a pellet, and a powder.

4. The method for manufacturing a vehicle steering hanger according to any one of Claims 1 to 3, wherein the metal member is a steering hanger beam, the resin member is a plurality of mounting members for mounting each of a plurality of parts supported by the steering hanger beam, and each of the resin members is bonded to the surface of the metal member.

5. The method for manufacturing a vehicle steering hanger according to any one of Claims 1 to 4, wherein the metal member is made of an extruded aluminum material of an A6000 series alloy and has characteristics of a tensile strength of 180 MPa or more and a Young's modulus of 60 GPa or more.

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