JP7319610B2 - 複合部材の製造方法、及び複合部材 - Google Patents
複合部材の製造方法、及び複合部材 Download PDFInfo
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- JP7319610B2 JP7319610B2 JP2019025320A JP2019025320A JP7319610B2 JP 7319610 B2 JP7319610 B2 JP 7319610B2 JP 2019025320 A JP2019025320 A JP 2019025320A JP 2019025320 A JP2019025320 A JP 2019025320A JP 7319610 B2 JP7319610 B2 JP 7319610B2
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- aluminum
- blasting
- aluminum member
- resin
- composite
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- 239000002131 composite material Substances 0.000 title claims description 51
- 238000004519 manufacturing process Methods 0.000 title claims description 37
- 229910052782 aluminium Inorganic materials 0.000 claims description 152
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 152
- 238000005422 blasting Methods 0.000 claims description 79
- 239000011347 resin Substances 0.000 claims description 65
- 229920005989 resin Polymers 0.000 claims description 65
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 49
- 230000033444 hydroxylation Effects 0.000 claims description 34
- 238000005805 hydroxylation reaction Methods 0.000 claims description 34
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 29
- 238000000034 method Methods 0.000 claims description 23
- 229910001593 boehmite Inorganic materials 0.000 claims description 13
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical group O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 13
- 239000006061 abrasive grain Substances 0.000 claims description 11
- 238000010335 hydrothermal treatment Methods 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 4
- 238000002347 injection Methods 0.000 description 88
- 239000007924 injection Substances 0.000 description 88
- 239000000463 material Substances 0.000 description 49
- 238000012545 processing Methods 0.000 description 19
- 230000000052 comparative effect Effects 0.000 description 15
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 13
- 229910052799 carbon Inorganic materials 0.000 description 13
- 239000007789 gas Substances 0.000 description 13
- 238000003860 storage Methods 0.000 description 13
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 11
- 230000008569 process Effects 0.000 description 11
- 239000000428 dust Substances 0.000 description 10
- 230000000694 effects Effects 0.000 description 10
- 238000001746 injection moulding Methods 0.000 description 8
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- 238000004458 analytical method Methods 0.000 description 6
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- 239000000203 mixture Substances 0.000 description 6
- 229920000069 polyphenylene sulfide Polymers 0.000 description 6
- 239000011148 porous material Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 239000004734 Polyphenylene sulfide Substances 0.000 description 5
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000012790 confirmation Methods 0.000 description 4
- 238000001514 detection method Methods 0.000 description 4
- 239000001257 hydrogen Substances 0.000 description 4
- 229910052739 hydrogen Inorganic materials 0.000 description 4
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 4
- 230000006872 improvement Effects 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 125000004430 oxygen atom Chemical group O* 0.000 description 4
- 238000011109 contamination Methods 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000004381 surface treatment Methods 0.000 description 3
- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 238000004833 X-ray photoelectron spectroscopy Methods 0.000 description 2
- 238000004873 anchoring Methods 0.000 description 2
- 238000005102 attenuated total reflection Methods 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- -1 polybutylene terephthalate Polymers 0.000 description 2
- 238000002407 reforming Methods 0.000 description 2
- 238000000682 scanning probe acoustic microscopy Methods 0.000 description 2
- 230000005514 two-phase flow Effects 0.000 description 2
- 229920000106 Liquid crystal polymer Polymers 0.000 description 1
- 239000004977 Liquid-crystal polymers (LCPs) Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 238000002835 absorbance Methods 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000013043 chemical agent Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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- 238000010008 shearing Methods 0.000 description 1
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- 239000007921 spray Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
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- 238000004506 ultrasonic cleaning Methods 0.000 description 1
Images
Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Description
図1は、実施形態に係る複合部材1を示す斜視図である。図1に示されるように、複合部材1は、複数の部材が接合により一体化された部材である。例えば、複合部材1は、樹脂部材と、樹脂部材に対する異種部材とを接合させた部材である。樹脂部材に対する異種部材とは、熱膨張率、熱伝達率、強度などが樹脂部材に対して異なる性質を有する材料で形成された部材である。
複合部材1の製造方法に用いる装置概要を説明する。最初に、アルミ部材2の表面にブラスト加工を行う装置を説明する。ブラスト加工装置は、重力式(吸引式)のエアブラスト装置、直圧式(加圧式)のエアブラスト装置、遠心式のブラスト装置、等何れのタイプを用いてもよい。本実施形態に係る製造方法は、一例として、いわゆる直圧式(加圧式)のエアブラスト装置を用いる。図3は、複合部材1の製造方法に用いるブラスト加工装置10の概念図である。ブラスト加工装置10は、処理室11、噴射ノズル12、貯留タンク13、加圧室14、圧縮気体供給機15及び集塵機(不図示)を備える。
上記実施形態に係るアルミ部材2及び樹脂部材3として、板状部材を例として示したが、形状に限定されることはなく、互いに接触可能なあらゆる形状を採用することができる。上記実施形態に係る樹脂部材3は、アルミ部材2の表面の一部に接触していたが、アルミ部材2の表面全てに接触していてもよい。
射出成形は、インサート成形に限定されるものではなく、アウトサート成形であってもよい。
最初にブラスト加工工程(S12)を実行する前のアルミ部材2の酸化被膜の膜厚を計測した。「オージェ電子分光法(AES:Auger electron spectroscopy)」を用いてアルミ酸化皮膜の深さ方向分析を行った。酸化物/金属の界面付近では酸化物と金属成分が同時に検出されるためにこれらをスペクトル合成法によって分離して、酸化被膜の膜厚を求めた。酸化被膜の膜厚は72nmであった。次に、図3~図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行後、アルミ部材2の酸化被膜の膜厚を計測した。砥粒の中心粒径が600μm~710 μmの噴射材を用いた場合、酸化被膜の膜厚は13 nmであった。砥粒の中心粒径が41 μm~50 μmの噴射材(最大粒子径127 μm以下、平均粒子径57μm ± 3 μm)を用いた場合、酸化被膜の膜厚は9 nmであった。このため、少なくとも710 μm以下の噴射材を用いることで、アルミ部材2の表面2aの酸化被膜を除去できることが確認された。
図3~図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行した。アルミ部材は、アルミニウム板(JIS(Japanese Industrial Standards):A5052)を用いた。ブラスト加工には、材料がアルミナ、砥粒中心粒径が106μm~125μmの噴射材を用いた。ブラスト圧は1.0 MPaとした。ブラスト加工工程後に、電界放出形走査電子顕微鏡(FE-SEM:FieldEmission Scanning Electron Microscope)を用いて表面観察した。
[実施例:表面処理品]
図3~図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行した。アルミ部材は、アルミニウム板(JIS:A5052)を用いた。ブラスト加工には、材料がアルミナ、砥粒中心粒径が106μm~125μmの噴射材を用いた。ブラスト圧は1.0 MPaとした。続いて、表面水酸化工程(S14)を実行した。ブラスト加工されたアルミニウム板を90℃の純水に5分間浸漬させた。
[比較例:未処理品]
ブラスト加工工程(S12)および表面水酸化工程(S14)を実行していないアルミニウム板(JIS:A5052)とした。
表面水酸化工程(S14)を実行したアルミ部材2の表面炭素濃度と、未処理品の表面炭素濃度とを計測し、比較した。計測にはX線光電子分光法(XPS:X-rayPhotoelectron Spectroscopy)を用いた。その結果、未処理品の表面炭素濃度は40 at%であったのに対して、表面水酸化工程(S14)を実行したアルミ部材2の表面炭素濃度は8at%となった。このように、水熱処理の二次的効果として洗浄効果があることが確認された。
実施例及び比較例1~3を用意してせん断強度を確認した。
[実施例]
図3~図5に示されるブラスト加工装置を用いてブラスト加工工程(S12)を実行した。アルミ部材は、アルミニウム板(JIS:A5052)を用いた。ブラスト加工には、材料がアルミナ、砥粒中心粒径が106μm~125μmの噴射材を用いた。ブラスト圧は1.0 MPaとした。続いて、表面水酸化工程(S14)を実行した。ブラスト加工されたアルミニウム板を90℃の純水に5分間浸漬させた。続いて、接合工程(S16)を実行した。図6及び図7に示される金型20を用いて、アルミ部材2に樹脂部材3を接合させた。樹脂部材3は、縦、横、厚さが10mm×45 mm×3.0 mmとなるように設定した。樹脂部材3の材料は、ポリフェニレンサルファイド樹脂(PPS)を用いた。樹脂部材3として、成分の異なる3つのPPSを用意した。出射時において、金型温度は150℃、出射速度は20mm/s、出射圧力は53~93 MPa、出射時間は0.56 sとした。保持時において、保持圧力は80MPa、保持時間は8 sとした。アルミ部材2と樹脂部材3との重なりは5mmとした。
[比較例1~3]
比較例1は、アルミ部材として、ブラスト加工工程(S12)および表面水酸化工程(S14)を実行していないアルミニウム板(JIS:A5052)を用いた。接合工程(S16)は実施例と同一とした。
比較例2は、アルミ部材として、ブラスト加工工程(S12)を実行せず、実施例と同一の表面水酸化工程(S14)を実行したアルミニウム板(JIS:A5052)を用いた。接合工程(S16)は実施例と同一とした。
比較例3は、アルミ部材として、実施例と同一のブラスト加工工程(S12)を実行し、表面水酸化工程(S14)を実行していないアルミニウム板(JIS:A5052)を用いた。接合工程(S16)は実施例と同一とした。
上記条件で作成された実施例及び比較例1~3のせん断強度を測定した。評価装置は、ISO 19095に準拠した試験方法で測定した。測定結果を図14に示す。
Claims (6)
- アルミ部材と樹脂部材とを接合した複合部材の製造方法であって、
前記アルミ部材の表面をブラスト加工し、前記アルミ部材の表面にマイクロオーダー又はナノオーダーの凹凸を形成するブラスト加工工程と、
前記ブラスト加工された前記アルミ部材の表面と水とを、熱及びプラズマの少なくとも一方を用いて反応させて、前記アルミ部材の表面をアルミ水酸化物に改質する表面水酸化工程と、
前記アルミ水酸化物に改質された前記アルミ部材の表面に前記樹脂部材を直接接合する接合工程と、
を含み、
前記表面水酸化工程では、前記水により前記アルミ部材の表面を洗浄するとともに、前記アルミ部材の表面を前記アルミ水酸化物に改質する、
複合部材の製造方法。 - 前記ブラスト加工工程では、算術平均傾斜RΔa及び二乗平均平方根傾斜RΔqがそれぞれ0.17~0.50、0.27~0.60に制御された凹凸を形成する、請求項1に記載の複合部材の製造方法。
- アルミ部材と樹脂部材とを接合した複合部材の製造方法であって、
前記アルミ部材の表面をブラスト加工するブラスト加工工程と、
前記ブラスト加工された前記アルミ部材の表面と水とを、熱及びプラズマの少なくとも一方を用いて反応させて、前記アルミ部材の表面をアルミ水酸化物に改質する表面水酸化工程と、
前記アルミ水酸化物に改質された前記アルミ部材の表面に前記樹脂部材を直接接合する接合工程と、
を含み、
前記表面水酸化工程では、前記水により前記アルミ部材の表面を洗浄するとともに、前記アルミ部材の表面を前記アルミ水酸化物に改質し、
前記アルミ水酸化物はベーマイトである、複合部材の製造方法。 - 前記表面水酸化工程では、前記水に超音波を印加する、請求項1~3の何れか一項に記載の複合部材の製造方法。
- 前記表面水酸化工程は、水熱処理、水蒸気処理、過熱水蒸気処理、液中プラズマ及び水を混入させた大気圧プラズマの何れか1つを用いて前記アルミ部材の表面と水とを反応させる、請求項1~4の何れか一項に記載の複合部材の製造方法。
- アルミ部材と樹脂部材とを接合した複合部材の製造方法であって、
前記アルミ部材の表面をブラスト加工するブラスト加工工程と、
前記ブラスト加工された前記アルミ部材の表面と水とを、熱及びプラズマの少なくとも一方を用いて反応させて、前記アルミ部材の表面をアルミ水酸化物に改質する表面水酸化工程と、
前記アルミ水酸化物に改質された前記アルミ部材の表面に前記樹脂部材を直接接合する接合工程と、
を含み、
前記表面水酸化工程では、前記水により前記アルミ部材の表面を洗浄するとともに、前記アルミ部材の表面を前記アルミ水酸化物に改質し、
前記ブラスト加工工程で用いられる砥粒の粒子径は、30 μm~710 μmである、複合部材の製造方法。
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