Laminate and method for manufacturing the laminate

Abstract

To provide a laminate and a method for manufacturing a laminate which enable bonding of different materials.SOLUTION: A laminate is formed by laminating a first member containing metal, a second member containing a thermoplastic resin, and metal films arranged between opposite surfaces of the first member and the second member.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] Embodiments of the present invention relate to a laminate and a method for manufacturing the laminate.

Background Art

[0002] Carbon fiber reinforced thermoplastic (CFRTP) based on thermoplastic resin has a good balance of mass productivity, weight, and strength, and its applications are expanding mainly in automobiles and electronic devices. However, CFRTP also has demerits such as less freedom in shape and lower heat resistance temperature compared to metals. Therefore, the concept of multi-material that combines metal and CFRTP in the right place has been proposed, and the development of technologies for joining metal and CFRTP with high reliability has also become active. For example, metals are joined by conventional fusion welding, and carbon fiber reinforced composites (CFRP) based on metal and thermosetting resin are joined using an adhesive. However, the thermoplastic resin that forms the base of CFRTP does not have active functional groups on the resin surface, and generally, joining CFRTP to each other or joining different materials such as CFRTP to other materials is difficult.

[0003] In order to realize joining of different materials such as CFRTP, a material containing thermoplastic resin, and other materials, for example, a proposal has been made to generate reactive functional groups on the surface of the thermoplastic resin and then irradiate and heat the resin / metal interface with a laser to melt the thermoplastic resin to join different materials. However, the method of introducing functional groups into the joining surface and melting and joining using a heat source such as a laser has different methods and conditions for introducing functional groups depending on the types of thermoplastic resin and metal, and there are also combinations that cannot be joined in some cases, so it has poor versatility.

[0004] In addition, a proposal has been made to realize joining by the anchor effect in which CFRTP enters the fine irregularities on the metal surface by press-filling CFRTP melted together with metal into a mold. However, the method of press-filling CFRTP melted together with metal into a mold has limitations in the size that can be manufactured, and for example, construction at the manufacturing site is impossible, so the applicable products are severely restricted and it has poor versatility.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The problem to be solved by the present invention is to provide a laminate capable of joining different materials and a method for manufacturing the laminate.

Means for Solving the Problems

[0007] A laminate according to one embodiment includes a first member containing a metal, a second member containing a thermoplastic resin, and is disposed between opposing surfaces of the first member and the second member , a plurality of metal films respectively formed on the opposing surfaces of the first member and the second member; and is provided by laminating. The metal film includes a bonding layer made of Au and an adhesion layer made of at least one of Cr, V, Ti, and Ni, and the bonding layer of the first member and the bonding layer of the second member are joined together facing each other.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0009] Hereinafter, the bonded body 1 and the manufacturing method of the bonded body 1 according to an embodiment will be described with reference to FIGS. 1 to 3. FIG. 1 is an explanatory view showing the configuration of the laminate according to the embodiment. FIG. 2 is an explanatory view showing an enlarged configuration of the joint portion of the bonded body. FIG. 3 is an explanatory view showing the method of the tensile test of the bonded body 1, and FIG. 4 is an explanatory view showing the method of the tensile test of the bonded body 100 according to the comparative example. In addition, for the sake of explanation in each figure, the configuration is appropriately enlarged, reduced, or omitted. The arrows X, Y, and Z in the figure respectively indicate three mutually orthogonal directions. Here, X is along the tensile direction in the tensile test, and Z is along the lamination direction of the first member 10 and the second member 20.

[0010] As shown in FIG. 1, the bonded body 1 as a laminate includes a first member 10 containing a metal, a second member 20 containing a thermoplastic resin, and a bonding film 30 as a metal-containing laminate film. The first member 10 and the second member 20 are joined to each other by the bonding film 30 in a region where the bonding film 30 is disposed therebetween, constituting a joint portion 40.

[0011] The first member 10 is made of, for example, a material containing a metal, and is configured in a plate shape having a predetermined thickness. As the first member 10, for example, an Al-Mg-based aluminum alloy plate is used. One main surface of the first member configured in a plate shape as an example becomes the bonding surface 11.

[0012] The second member 20 is made of a thermoplastic resin or a material containing a thermoplastic resin, and is configured in a plate shape, for example. As the second member 20, for example, a nylon-based carbon fiber composite material plate is used. The other main surface of the second member 20 configured in a plate shape as an example becomes the bonding surface 21. The second member 20 is disposed so as to overlap one side in the lamination direction of the first member 10.

[0013] The bonding film 30 is a metal film interposed between the first member 10 and the second member 20. The bonding film 30 may be composed of a metal thin film 31 formed on either the first member 10 or the second member 20, or may be composed of a laminate of a plurality of metal thin films 31, 31 formed on each of the first member 10 and the second member 20. Further, the metal thin films 31 constituting the bonding film 30 may each have a single-layer structure, or may have a laminated structure having two or more layers. Alternatively, among the pair of metal thin films 31, 31 constituting the bonding film 30, only one may have a single-layer structure and the other may have a laminated structure. As the metal constituting the bonding film 30, for example, metals such as Au, Ti, V, and Cr are used. Alternatively, each layer may be composed of an alloy containing a plurality of metals such as Au, Ti, V, and Cr.

[0014] In the example shown in FIG. 2, metal thin films 31 are formed on the bonding surface 11 of the first member and the bonding surface 21 of the second member 20, respectively. Each metal thin film 31 has a laminated structure having a first layer 31a and a second layer 31b, and a bonding film 30 having a four-layer structure is formed. For example, the first layer 31a of the metal thin film 31 is an adhesion layer formed on the surface of the first member 10 or the second member 20, and the second layer 31b is a bonding layer formed on the adhesion layer. For example, the first layer 31a serving as the adhesion layer is a single-layer film formed of any one of Cr, V, Ti, and Ni, or a laminated structure including a plurality of thin films composed of any one of these metals, and the second layer 31b serving as the bonding layer is composed of Au.

[0015] Hereinafter, a method for manufacturing the bonded body 1 according to the present embodiment will be described. First, a metal thin film 31 is formed on at least one of the bonding surfaces 11, 21 to be bonded of the first member 10 and the second member 20 configured in a predetermined shape. The metal thin film 31 may be formed on both the first member 10 and the second member 20. The metal thin film 31 is formed on the bonding surfaces 11, 21 by, for example, a vapor deposition method or a plating method.

[0016] Subsequently, the bonding surface 11 of the first member 10 and the bonding surface 21 of the second member 20 are laminated with a metal thin film 31 interposed therebetween, and are heated and pressed to soften at least one of the first member 10 and the second member 20, thereby closely adhering and bonding the bonding surfaces at the atomic level. The pressing process is, for example, pressed in a direction in which the first member 10 and the second member 20 are brought closer to each other in the lamination direction. The bonding surface 11 of the first member 10 and the bonding surface 21 of the second member 20 are firmly bonded by the formation of a metal bond between the thin films due to the proximity of the metal thin films 31 formed on each of them at the atomic level. For example, as a method of heating and pressing the first member 10 and the second member 20 to soften and adhere at least one of them, heat-pressure bonding in which they are placed in a mold of a hot press machine and heated and pressed at a predetermined pressure and a predetermined temperature °C for a predetermined time, or a method applying friction stir welding (FSW) in which heat is generated by friction when a tool called a tool rotating at high speed is pressed against the member can be used.

[0017] For example, the heating temperature is a temperature at which the second member 20 is softened or melted while the bonding film 30 is held on the bonding surfaces 11 and 21 of the first member 10 and the second member 20 that are the bonding targets. As an example, it is set to a temperature close to the melting point of the resin that forms the base of the second member 20, for example, a temperature within a predetermined range from the melting point temperature.

[0018] As described above, the first member 10 and the second member 20 are bonded by the bonding film 30, and the bonded body 1 is obtained.

[0019] According to the bonded body 1 configured as described above, it is possible to provide a laminate capable of bonding different materials to each other and a method for manufacturing the laminate. That is, by disposing a laminated film containing a metal therebetween, different materials such as the first member 10 containing a metal and the second member containing a thermoplastic resin can be easily and firmly bonded. In addition, there are no restrictions on the materials of the members 10 and 20 to be bonded and the size of the bonding surface, and it can be applied to various materials and sizes, and has high versatility.

[0020] Regarding the joined body 1 according to the above embodiment, a plurality of examples and examples of evaluation tests for each example are shown below. Further, as Comparative Examples 10 and 11, measurement results of a joined body 100 in which the first member 110 and the second member 120 are joined without forming the joining film 30 are shown.

[0021] In the tensile test, spacers 41 with a thickness of 5 mm were installed at both ends of the joined bodies 1 and 100, that is, at the end of the first member 10 and the end of the second member 20, and both ends of the joined bodies 1 and 100 were set as chucking positions 42, respectively. In the tensile test, as shown in FIG. 3, both ends of the joined body 1 were chucked together with the spacers 41 into a tensile testing machine and pulled in the X direction intersecting the lamination direction at a speed of 5 mm per minute, the breaking strength was measured, and the fracture surface was observed.

[0022] [Example 1] In Example 1, as the first member 10, an Al-Mg-based aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. As the second member 20, a nylon-based carbon fiber composite material plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The joining film 30 is composed of a laminate of a pair of metal thin films 31 each formed in a 50 mm square region from one end in the length direction of the joining surfaces 11 and 21. For both metal thin films 31 and 31 constituting the joining film 30, Ti was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a joining layer. In this example, by the vacuum evaporation method, a Ti layer with a thickness of 1 nm and an Au layer with a thickness of 1 nm were sequentially formed on each of the joining surfaces 11 and 21 to obtain the metal thin films 31 and 31. The joining surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated, and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 200 °C for 5 minutes to join them, thereby fabricating the joined body 1. As a result of the above-described tensile test, the breaking strength was 1 MPa or less.

[0023] [Example 2] In Example 2, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. As the second member 20, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31, 31 constituting the bonding film 30, Ti was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by forming a Ti layer with a thickness of 5 nm and an Au layer with a thickness of 5 nm in sequence on each of the bonding surfaces 11 and 21 by vacuum evaporation, the metal thin films 31, 31 were obtained. The bonding surfaces 11, 21 on which the metal thin films 31 were formed were butted together, the first member 10 and the second member 20 were laminated and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 200 °C for 5 minutes to be bonded, whereby the bonded body 1 was produced. As a result of the above-mentioned tensile test, the breaking strength was 1 MPa or less.

[0024] [Example 3] In Example 3, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. As the second member 20, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31, 31 constituting the bonding film 30, Ti was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by forming a Ti layer with a thickness of 5 nm and an Au layer with a thickness of 5 nm in sequence on the bonding surfaces 11 and 21 by vacuum evaporation, the metal thin films 31, 31 were obtained. The bonding surfaces 11, 21 on which the metal thin films 31 were formed were butted together, the first member 10 and the second member 20 were laminated and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to be bonded, whereby the bonded body 1 was produced. As a result of the above-mentioned tensile test, the breaking strength was about 11 MPa. When the fracture surface after the test was observed, interfacial delamination occurred between the laminated film and the surface of the carbon fiber composite material.

[0025] [Example 4] In Example 4, as the first member 10, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. As the second member 20, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 5 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to bond the first member 10 and the second member 20, thereby fabricating the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was about 18 MPa. When the fracture surface after the test was observed, delamination occurred between the bonding film 30 and the surface of the carbon fiber composite which is the second member 20.

[0026] [Example 5] In Example 5, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. As the second member 20, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 each formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum deposition method, a Cr layer with a thickness of 5 nm as the first layer 31a and an Au layer with a thickness of 5 nm as the second layer 31b were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated, and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 10 minutes to bond the first member 10 and the second member 20, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength of the bonded body 1 was about 17 MPa. When the fracture surface after the test was observed, delamination occurred between the laminated film and the surface of the carbon fiber composite material.

[0027] [Example 6] In Example 6, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. As the second member 20, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 each formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum deposition method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11, 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to be bonded, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was about 29 MPa. When the fracture surface after the test was observed, the matrix had broken with nylon on the surface of the carbon fiber composite material.

[0028] [Example 7] In Example 7, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. As the second member 20, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31 and 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31 and 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were butted together, the first member 10 and the second member 20 were laminated, and placed in a mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 230 °C for 5 minutes to be bonded, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was about 10 MPa. When the fracture surface after the test was observed, in some regions, it fractured at the interface between the carbon fiber composite and nylon in the second member 20. It is considered that the nylon which is the base of the carbon fiber composite eluted during pressurization, causing thermal degradation of the carbon fiber composite and a decrease in the breaking strength.

[0029] [Example 8] In Example 8, as the first member, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used, and as the second member, a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used. The bonding film 30 was formed in a 50 mm square region from one end in the length direction of the bonding surface 11 of the first member 10. The bonding film 30 was a single-layer film of Cr. In this example, a single-layer film of Cr (10 nm) was formed on the bonding surface 11 of the first member 10. The surface of the aluminum alloy plate which is the first member 10 on which the bonding film 30 was formed and the surface of a 50 mm square region from one end in the length direction of the second member 20 were butted together, placed in a mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to be bonded, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was 1 MPa or less.

[0030] [Example 9] In Example 9, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used for the first member 10. A nylon plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the second member 20. The bonding films 30 were sequentially formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 respectively formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated and placed in a mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 230 °C for 5 minutes to perform bonding, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was about 10 MPa. The nylon plate was greatly deformed due to the melting of nylon. When the fracture surface after the test was observed, the base material had fractured with nylon.

[0031] [Example 10] In Example 10, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10, and a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the second member 20. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 each formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11, 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated, the first member 10 was fixed with a jig as the upper surface, and a cylindrical rotating tool was pressed against the upper surface of the aluminum alloy plate, and joined by rotation and pressurization to obtain the joined body 1. The rotation speed was 1000 rpm, the load was about 5000 N, and the pressing time was 15 seconds. As a result of the above-mentioned tensile test, the breaking strength was about 31 MPa. When the fracture surface after the test was observed, the matrix had broken with nylon on the surface of the carbon fiber composite material.

[0032] [Example 11] In Example 11, a low-carbon steel plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. A nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the second member 20. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11, 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated, and placed in a mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to be bonded, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was about 30 MPa. When the fracture surface after the test was observed, the matrix had fractured with nylon on the surface of the carbon fiber composite material.

[0033] [Example 12] In Example 12, an Mg-Al-Zn-Ca-based magnesium alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. A nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the second member 20. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31 and 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31 and 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, and the first member 10 and the second member 20 were laminated and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to be bonded, thereby producing the bonded body 1. As a result of the above-mentioned tensile test, the breaking strength was about 28 MPa. When the fracture surface after the test was observed, the matrix had fractured with nylon on the surface of the carbon fiber composite material.

[0034] [Example 13] In Example 13, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. A polypropylene-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the second member 20. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21, respectively. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by the vacuum evaporation method, a Cr layer with a thickness of 10 nm and an Au layer with a thickness of 5 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated, and placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 180 °C for 5 minutes to be bonded, thereby producing the bonded body 1. As a result of the above tensile test, the breaking strength was about 10 MPa. When the fracture surface after the test was observed, the base material was fractured by polypropylene on the surface of the carbon fiber composite material.

[0035] [Example 14] In Example 14, an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm was used as the first member 10. As the second member 20, a nylon-based carbon fiber composite plate was used. The bonding film 30 is composed of a laminate of a pair of metal thin films 31 each formed in a 50 mm square region from one end in the length direction of the bonding surfaces 11 and 21. For both metal thin films 31, 31 constituting the bonding film 30, Cr was used as the first layer 31a which is an adhesion layer, and Au was used as the second layer 31b which is a bonding layer. In this example, by plating, a Cr layer with a thickness of 100 nm and an Au layer with a thickness of 50 nm were sequentially formed on each of the bonding surfaces 11 and 21 to obtain the metal thin films 31, 31. The bonding surfaces 11 and 21 on which the metal thin films 31 were formed were abutted, the first member 10 and the second member 20 were laminated and placed in a mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210 °C for 5 minutes to join them, thereby manufacturing the joined body 1. As a result of the above tensile test, the breaking strength was about 25 MPa. When the fracture surface after the test was observed, in some regions, the nylon on the surface of the carbon fiber composite material broke the base material.

[0036] [Comparative Example 10] As a comparative example, the 50 mm square regions from one end in the length direction of the bonding surfaces of an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm and a nylon-based carbon fiber composite plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm were abutted and placed in a mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 230 °C for 5 minutes to produce the joined body 100. Spacers 41 with a thickness of 5 mm were installed at both ends of the joined body 100, and the joined body together with the spacers 41 was chucked in a tensile testing machine and pulled at a speed of 5 mm per minute. As a result, the breaking strength was about 2 MPa. Due to the melting of the nylon, the nylon plate was greatly deformed.

[0037] [Comparative Example 11] As a comparative example, regions of 50 mm square were butted together from one end in the length direction of the joint surfaces of an Al-Mg series aluminum alloy plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm and a nylon plate with a width of 50 mm, a length of 100 mm, and a thickness of 5 mm, and the assembly was placed in the mold of a hot press machine, and heated and pressed at a pressure of 10 MPa and a temperature of 210°C for 5 minutes to produce a joined body 100. Spacers 41 with a thickness of 5 mm were installed at both ends of the joined body 100, and the joined body together with the spacers 41 was chucked in a tensile testing machine and pulled at a speed of 5 mm per minute. As a result, the breaking strength was about 1 MPa or less. No significant deformation was observed in the nylon plate.

[0038] According to the evaluation test results of the above examples, it can be seen that the joining strength of the first member 10 and the second member 20 can be obtained by joining through the joining film 30 which is a metal thin film. Therefore, according to the joined body 1 and its manufacturing method according to the above embodiment, a laminate capable of joining different materials and a manufacturing method of the laminate can be provided.

[0039] Note that the present embodiment is not limited to the examples described above, and it is possible to implement by appropriately changing the shape and material of each part.

[0040] Although some embodiments of the present invention have been described, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalent scope thereof. The following is an appended description equivalent to the invention described in the claims of the present application at the initial filing. (1) A first member containing a metal; A second member containing a thermoplastic resin; A metal film disposed between the opposing surfaces of the first member and the second member; A laminate comprising the above layers. (2) The laminate according to (1), wherein the first member and the second member are joined by the metal film. (3) The laminate according to (1) or (2), wherein the metal film includes a bonding layer made of Au and an adhesion layer made of at least one of Cr, V, Ti, and Ni. (4) A metal film is formed on at least one or both surfaces of a first member containing a metal and a second member containing a thermoplastic resin; A method for manufacturing a laminate, wherein the first member and the second member are opposed to each other via the metal film and are pressure-bonded by heating and pressurizing or by friction. (5) The method for manufacturing a laminate according to (4), wherein the metal film includes a bonding layer made of Au and an adhesion layer made of at least one of Cr, V, Ti, and Ni. (6) The method for manufacturing a laminate according to (4) or (5), wherein the metal film is formed on at least one of the surfaces of the first member and the second member by vapor deposition or plating.

Description of Symbols

[0041] 1... Assembly, 10... First member, 11... Bonding surface, 20... Second member, 21... Bonding surface, 30... Bonding film, 31... Metal thin film, 31a... First layer, 31b... Second layer, 40... Bonding portion, 41... Spacer, 42... Chucking position, 100... Assembly, 110... First member, 120... Second member.

Claims

1. a first member containing a metal; a second member containing a thermoplastic resin; a plurality of metal films disposed between the opposing surfaces of the first member and the second member and formed on the opposing surface of the first member and the opposing surface of the second member, respectively; which are laminated; the metal film includes an adhesion layer made of any one or more of Cr, V, Ti, and Ni and a bonding layer made of Au laminated thereon; a laminate in which the bonding layer of the first member and the bonding layer of the second member are opposed and bonded.

2. The laminate according to claim 1, wherein the first member and the second member are bonded by the metal film.

3. A metal film including an adhesion layer made of any one or more of Cr, V, Ti, and Ni and a bonding layer made of Au is formed on both surfaces of a first member containing a metal and a second member containing a thermoplastic resin, respectively; A method for manufacturing a laminate, wherein the bonding layer of the metal film of the first member and the bonding layer of the metal film of the second member are opposed and pressure-bonded by heating and pressurizing or by friction.

4. The method for manufacturing a laminate according to claim 3, wherein the metal film is formed on at least one of the surfaces of the first member and the second member by vapor deposition or plating.

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