U.S. patent application number 12/922069 was filed with the patent office on 2011-01-13 for bonded body of galvanized steel sheet and adherend, and manufacturing method thereof.
This patent application is currently assigned to TAISEI PLAS CO., LTD.. Invention is credited to Naoki Andoh, Masanori Naritomi.
Application Number | 20110008644 12/922069 |
Document ID | / |
Family ID | 41090887 |
Filed Date | 2011-01-13 |
United States Patent
Application |
20110008644 |
Kind Code |
A1 |
Naritomi; Masanori ; et
al. |
January 13, 2011 |
BONDED BODY OF GALVANIZED STEEL SHEET AND ADHEREND, AND
MANUFACTURING METHOD THEREOF
Abstract
The invention is a technique for strongly integrating a
galvanized steel sheet and a resin molded article. A hot-dip
galvanized steel sheet "Z18" is immersed in an aqueous solution for
aluminum degreasing at 75.degree. C. for 7 minutes, to form
roughness having an RSm of 0.8 to 2.3 .mu.m and an Rz of 0.3 to 1.0
.mu.m on the surface. The surface is covered with convex
protrusions having a diameter of about 100 nm, and a chromate
treatment layer appears in the surface. In other words, three
conditions suitable for bonding are satisfied thereby. A resin
composition comprising 70 to 97 wt % of polyphenylene sulfide and 3
to 30 wt % of a polyolefin resin is injected onto the surface. The
resin composition penetrates into ultra-fine irregularities and is
cured in that state, whereby a composite in which the galvanized
steel sheet and the resin molded article are strongly integrated is
obtained. The shear rupture strength of the composite is extremely
high, in excess of 20 MPa.
Inventors: |
Naritomi; Masanori; (Tokyo,
JP) ; Andoh; Naoki; (Tokyo, JP) |
Correspondence
Address: |
WESTERMAN, HATTORI, DANIELS & ADRIAN, LLP
1250 CONNECTICUT AVENUE, NW, SUITE 700
WASHINGTON
DC
20036
US
|
Assignee: |
TAISEI PLAS CO., LTD.
Tokyo
JP
|
Family ID: |
41090887 |
Appl. No.: |
12/922069 |
Filed: |
March 16, 2009 |
PCT Filed: |
March 16, 2009 |
PCT NO: |
PCT/JP2009/055016 |
371 Date: |
September 10, 2010 |
Current U.S.
Class: |
428/612 ;
216/100; 216/35; 216/37 |
Current CPC
Class: |
B29K 2105/06 20130101;
B32B 2270/00 20130101; B29C 45/14311 20130101; B29C 66/74283
20130101; B29K 2995/0072 20130101; B29K 2307/00 20130101; B29C
65/485 20130101; B29C 66/71 20130101; B29C 45/14008 20130101; B29C
66/73151 20130101; B29C 66/81821 20130101; B32B 15/18 20130101;
B32B 2262/106 20130101; C23C 22/56 20130101; B29C 66/71 20130101;
B29K 2705/00 20130101; B32B 3/26 20130101; B29C 65/44 20130101;
B32B 27/36 20130101; B29C 66/30325 20130101; B29K 2077/10 20130101;
B32B 27/34 20130101; B29C 66/7212 20130101; B32B 15/043 20130101;
B29C 65/8253 20130101; B32B 5/147 20130101; B29C 66/71 20130101;
B29C 66/7212 20130101; B29K 2081/04 20130101; C23C 2/26 20130101;
C23C 22/00 20130101; B29C 45/0001 20130101; C23C 22/30 20130101;
B29C 66/7212 20130101; B29C 66/7483 20130101; B29K 2101/12
20130101; C23C 22/362 20130101; B29C 66/0344 20130101; B29C 66/8122
20130101; B29K 2305/12 20130101; C23C 22/07 20130101; C23C 22/22
20130101; B29K 2827/18 20130101; B32B 27/20 20130101; B29C 66/7212
20130101; B32B 27/286 20130101; C23C 22/33 20130101; C23C 22/365
20130101; B29C 66/43 20130101; B29C 66/71 20130101; C23C 22/50
20130101; B29C 66/73111 20130101; B29C 65/4835 20130101; B29K
2305/00 20130101; B32B 2255/26 20130101; B32B 2307/536 20130101;
B29C 66/02245 20130101; B29C 66/73775 20130101; B29C 66/8322
20130101; B32B 37/182 20130101; B05D 7/51 20130101; B29C 66/71
20130101; B29C 66/0042 20130101; C23C 22/12 20130101; B29K 2277/10
20130101; B29K 2307/04 20130101; B29C 65/483 20130101; C23F 1/00
20130101; B29C 65/00 20130101; B29C 66/73115 20130101; B29C 66/8248
20130101; B32B 37/12 20130101; B29C 45/14778 20130101; B29C 66/721
20130101; B32B 15/08 20130101; B32B 2255/06 20130101; B32B 2307/542
20130101; B32B 7/12 20130101; B32B 27/32 20130101; B32B 2262/101
20130101; B32B 2307/538 20130101; B32B 2419/00 20130101; C23C 22/06
20130101; C23C 22/53 20130101; B29C 66/73161 20130101; B29C 66/8122
20130101; B29C 66/7392 20130101; B29C 66/964 20130101; B29C 66/1122
20130101; B29C 2045/14868 20130101; B29C 66/71 20130101; B29C 66/71
20130101; B32B 2037/1269 20130101; B29C 66/026 20130101; B29C 65/48
20130101; B29K 2067/006 20130101; Y10T 428/12472 20150115; B29K
2067/003 20130101; B29K 2309/08 20130101; B29K 2081/04 20130101;
B29K 2023/00 20130101; B29K 2077/00 20130101; B29K 2077/10
20130101; B29K 2067/006 20130101 |
Class at
Publication: |
428/612 ;
216/100; 216/35; 216/37 |
International
Class: |
B32B 15/08 20060101
B32B015/08; C23F 1/00 20060101 C23F001/00; B32B 37/14 20060101
B32B037/14; B32B 38/00 20060101 B32B038/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 17, 2008 |
JP |
2008-067313 |
Claims
1. A bonded body of a galvanized steel sheet and an adherend,
wherein the surface of said galvanized steel sheet has micron-scale
roughness having a peak-valley average spacing (RSm) of 0.8 to 10
.mu.m and a maximum height roughness (Rz) of 0.2 to 5 .mu.m, and
ultra-fine irregularities having a period of 10 to 300 nm are
formed within the surface having the micron-scale roughness, the
surface layer being a thin layer of a metal oxide or a metal
phosphate, said adherend is a resin molded article of a
thermoplastic resin composition having, as a main component, one or
more selected from among polybutylene terephthalate, polyphenylene
sulfide and an aromatic polyamide, and said galvanized steel sheet
and said resin molded article are bonded by way of said
thermoplastic resin composition that penetrates into said
ultra-fine irregularities and is cured.
2. The bonded body of a galvanized steel sheet and an adherend
according to claim 1, wherein said thermoplastic resin composition
comprises 70 to 97 wt % of polybutylene terephthalate and 3 to 30
wt % of polyethylene terephthalate and/or a polyolefin resin.
3. The bonded body of a galvanized steel sheet and an adherend
according to claim 1, wherein said thermoplastic resin composition
comprises 70 to 97 wt % of polyphenylene sulfide and 3 to 30 wt %
of a polyolefin resin.
4. The bonded body of a galvanized steel sheet and an adherend
according to claim 1, wherein said thermoplastic resin composition
comprises 50 to 100 wt % of an aromatic polyamide and 0 to 50 wt %
of an aliphatic polyamide.
5. (canceled)
6. A bonded body of a galvanized steel sheet and an adherend,
wherein the surface of said galvanized steel sheet has micron-scale
roughness having a peak-valley average spacing (RSm) of 0.8 to 10
.mu.m and a maximum height roughness (Rz) of 0.2 to 5 .mu.m, and
ultra-fine irregularities having a period of 10 to 300 nm are
formed within the surface having the micron-scale roughness, the
surface layer being a thin layer of a metal oxide or a metal
phosphate, said adherend is a resin molded article of a hard,
highly crystalline resin having, as a main component, one or more
selected from among polybutylene terephthalate, polyphenylene
sulfide, an aromatic polyamide, an aliphatic polyamide and a liquid
crystal polymer, and said galvanized steel sheet and said resin
molded article are bonded by way of said highly crystalline resin
that penetrates into said ultra-fine irregularities and is
cured.
7-9. (canceled)
10. A bonded body of a galvanized steel sheet and an adherend,
wherein said adherend is a metal alloy, the surfaces of both said
galvanized steel sheet and said metal alloy have micron-scale
roughness having a peak-valley average spacing (RSm) of 0.8 to 10
.mu.m and a maximum height roughness (Rz) of 0.2 to 5 .mu.m, and
ultra-fine irregularities having a period of 10 to 300 nm are
formed within the surfaces having the micron-scale roughness, the
surface layers being thin layers of a metal oxide or a metal
phosphate, and the galvanized steel sheet and the metal alloy are
strongly bonded by way of a thermosetting adhesive, being one type
of thermosetting adhesive selected from among (1) to (3), namely
(1) an epoxy adhesive, (2) a phenolic adhesive and (3) an
unsaturated polyester adhesive, that penetrates into the ultra-fine
irregularities of both said galvanized steel sheet and said metal
alloy, and is cured in that state.
11. (canceled)
12. A method for manufacturing a bonded body of a galvanized steel
sheet and an adherend, comprising: a surface treatment step of
performing a liquid treatment for creating, on the surface of a
galvanized steel sheet, micron-scale roughness having a peak-valley
average spacing (RSm) of 0.8 to 10 .mu.m and a maximum height
roughness (Rz) of 0.2 to 5 .mu.m, forming ultra-fine irregularities
having a period of 10 to 300 nm within the surface having the
micron-scale roughness, and making the surface layer into a thin
layer of a metal oxide or a metal phosphate; an inserting step of
inserting the galvanized steel sheet, having undergone said surface
treatment step, into an injection molding mold; and an integrating
step of injecting a thermoplastic resin composition having, as a
main component, one or more selected from among polybutylene
terephthalate, polyphenylene sulfide and an aromatic polyamide,
onto the surface of said inserted galvanized steel sheet, and
curing the injected thermoplastic resin composition after having
penetrated into said ultra-fine irregularities, to thereby strongly
integrate said galvanized steel sheet and a molded article of the
thermoplastic resin composition.
13. A method for manufacturing a bonded body of a galvanized steel
sheet and an adherend, comprising: a surface treatment step of
performing a liquid treatment for creating, on the surface of a
galvanized steel sheet, micron-scale roughness having a peak-valley
average spacing (RSm) of 0.8 to 10 .mu.m and a maximum height
roughness (Rz) of 0.2 to 5 .mu.m, forming ultra-fine irregularities
having a period of 10 to 300 nm within the surface having the
micron-scale roughness, and making the surface layer into a thin
layer of a metal oxide or a metal phosphate; a resin molded article
production step of producing a resin molded article of a resin
composition having, as a main component, one or more selected from
among polybutylene terephthalate, polyphenylene sulfide, an
aromatic polyamide, an aliphatic polyamide and a liquid crystal
polymer; a heating step of heating the surface of the galvanized
steel sheet, having undergone said surface treatment step, to a
temperature not lower than a melting temperature of said resin
composition; and a press-fusion bonding step of pressing said resin
molded article against the surface of said galvanized steel sheet
having undergone said heating step, to put the resin composition in
a molten state, placing the galvanized steel sheet and the resin
molded article under reduced pressure, increasing the pressure
thereafter to cause the molten resin composition to penetrate into
said ultra-fine irregularities, and curing the resin that has
penetrated, to thereby fusion-bond the galvanized steel sheet and
the resin molded article.
14. A method for manufacturing a bonded body of a galvanized steel
sheet and an adherend, comprising: a surface treatment step of
performing a liquid treatment for creating, on the surface of a
galvanized steel sheet, micron-scale roughness having a peak-valley
average spacing (RSm) of 0.8 to 10 .mu.m and a maximum height
roughness (Rz) of 0.2 to 5 .mu.m, forming ultra-fine irregularities
having a period of 10 to 300 nm within the surface having the
micron-scale roughness, and making the surface layer into a thin
layer of a metal oxide or a metal phosphate; a coating step of
coating one type of thermosetting adhesive selected from among (1)
to (3), namely (1) an epoxy adhesive, (2) a phenolic adhesive and
(3) an unsaturated polyester adhesive, onto the surface of the
galvanized steel sheet having undergone said surface treatment
step; a joining preliminary step of placing the galvanized steel
sheet, having undergone said coating step, into a hermetic
container that is depressurized and then pressurized to cause the
applied thermosetting adhesive to penetrate into said ultra-fine
irregularities; a fixing step of closely adhering and fixing an
adherend to the surface of said galvanized steel sheet having
undergone said joining preliminary step; and a curing step of
heating said fixed galvanized steel sheet and adherend, to thereby
cure the adhesive component.
15-22. (canceled)
Description
TECHNICAL FIELD
[0001] The present invention relates to a bonded body of an
adherend and a galvanized steel sheet having high corrosion
resistance and used in, for instance, construction materials,
outdoor equipment, construction machinery parts and ordinary
machinery parts, and to a method for manufacturing the bonded body.
More particularly, the present invention relates to a composite in
which a galvanized steel sheet and a resin composition are
integrated through injection of the resin composition into the
galvanized steel sheet, to a bonded body in which a galvanized
steel sheet and a metal alloy are bonded together by way of an
adhesive, to a composite in which a galvanized steel sheet and a
resin molded article are bonded by way of an adhesive, to a
composite in which a galvanized steel sheet and a fiber-reinforced
plastic (hereafter "FRP") are bonded by way of an adhesive, and to
a method for manufacturing each of the foregoing.
BACKGROUND ART
[0002] Technologies for integrating metal alloys with resins are
required in manufacturing industries of a wide variety of parts and
members, for instance in aerospace, automobiles, domestic
appliances, industrial machinery and the like. Numerous adhesives
have been developed to meet these requirements. Various excellent
adhesives are known among these adhesives. For instance, adhesives
that bring out their functionality at normal temperature, or upon
heating, are used to integrally bond a metal alloy and a synthetic
resin. This method constitutes a standard bonding technique used at
present.
[0003] Other bonding methods that do not rely on adhesives have
also been studied. Examples of such technologies include, for
instance, methods for integrating aluminum alloys with
high-strength thermoplastic engineering resins, without any
intervening adhesive, for instance through injection of the resin.
The present inventors, for example, have proposed a method that
involves bonding simultaneously with resin molding, by injection or
the like (hereafter, "injection bonding"), wherein a thermoplastic
resin such as a polybutylene terephthalate resin (hereafter, "PBT")
or a polyphenylene sulfide resin (hereafter, "PPS") is injected and
bonded with an aluminum alloy (for instance, Patent documents 1 and
2). A bonding technology has also been disclosed (for instance, see
Patent document 3) in which holes are provided in the anodized skin
formed on the surface of an aluminum material, and a part of molded
body of a synthetic resin is forced into the holes, to be bonded
thereby to the aluminum material.
[0004] The principles of the injection bonding disclosed in Patent
documents 1 and 2 are as follows. An aluminum alloy is immersed in
a dilute aqueous solution of a water-soluble amine compound,
whereupon the aluminum alloy is finely etched by the weak basicity
in the aqueous solution. The above immersion results in the
formation of ultra-fine irregularities on the aluminum alloy
surface, and at the same time, in adsorption of amine compound
molecules onto the surface of the aluminum alloy. The aluminum
alloy thus treated is inserted into an injection mold, into which a
molten thermoplastic resin is then injected at high pressure.
[0005] The encounter between the thermoplastic resin and molecules
of the amine compound adsorbed to the aluminum alloy surface gives
rise to a chemical reaction. This chemical reaction suppresses the
physical reaction whereby the thermoplastic resin cools down
quickly, crystallizes and solidify when coming into contact with
the aluminum alloy that is held at a low mold temperature.
Crystallization and solidification of the resin are delayed
thereby, and the resin infiltrates into the ultra-fine
irregularities on the surface of the aluminum alloy. As a result,
the thermoplastic resin does not peel readily off the aluminum
alloy surface even when acted upon by an external force. The
aluminum alloy and the resin molded article become strongly
integrated as a result. In other words, the chemical reaction and
the physical reaction exhibit a competing reaction relationship to
each other. In this case, the chemical reaction takes precedence,
and the result is a strong injection bonding. In practice it is
found that PBT and PPS, which can react chemically with amine
compounds, are capable of undergoing injection bonding with
aluminum alloys. The above injection bonding mechanism has been
termed "NMT (acronym of nano-molding technology)" by the
inventors.
[0006] Patent document 1: WO 03/064150 A1 (aluminum alloy)
[0007] Patent document 2: WO 2004/041532 A1 (aluminum alloy)
[0008] Patent document 3: WO 2004/055248 A1 (anodized skin)
[0009] Patent document 4: Japanese Patent Application Laid-open NO.
2001-225352
[0010] Galvanized steel sheets (ordinarily referred to as
zinc-plated steel sheets) are used as a construction material that
can be used for 10 years or longer without maintenance. The types
ordinarily used at present include precoated steel sheets (also
referred to as color steel sheets or color iron sheets) in which
one, two or three coats are baked onto a galvanized steel sheet.
These sheets exhibit good post-workability and corrosion
resistance. The range of applications of galvanized steel sheets,
as a construction material, could be expanded if the galvanized
steel sheets could be strongly integrated with an adherend such as
a resin molded article, FRP, metal alloys and the like. For
instance, the steel sheet portion of a composite wherein a
galvanized steel sheet and a resin molded article or FRP are
strongly integrated with each other could be connected to other
construction materials by way bolting, welding or the like. An
entire composite obtained from a resin molded article or FRP can
take on numerous shapes. The weight of the composite as a whole,
moreover, can be reduced by increasing the volume ratio of the
resin molded article or FRP. Such a composite is thus extremely
useful as a construction material. Meanwhile, strong bonding
between a galvanized steel sheet and a metal alloy by way of an
adhesive, without relying on bolting or welding, would contribute
to reducing costs on account of the fewer parts and fewer processes
that would be involved.
[0011] However, the above-described strong integration between an
aluminum alloy and resin molded articles is achieved through
adsorption of amine compounds onto the aluminum alloy surface.
Therefore, it is unclear whether galvanized steel sheets can be
injection-bonded in the same way as in the case of aluminum alloys,
inasmuch as galvanized steel sheets have different surface
environments, and are subjected to different immersion treatments,
vis-a-vis aluminum alloys. No techniques have been proposed for
strongly joining galvanized steel sheets and resin molded articles
by way of adhesives or through press-fusion bonding. Likewise, no
techniques have been proposed for strongly bonding galvanized steel
sheets and metal alloys or FRP by way of adhesives.
DISCLOSURE OF THE INVENTION
[0012] In the light of this technical background, it is an object
of the present invention to provide a technique for strongly
integrating a galvanized steel sheet and an adherend. Specifically,
it is an object of the present invention to strongly integrate a
galvanized steel sheet and a resin molded article through injection
bonding of a galvanized steel sheet and a thermoplastic resin
composition. It is another object of the present invention to
integrate a galvanized steel sheet and a molded article of a
thermoplastic resin composition through press-fusion bonding of the
foregoing. Yet another object of the present invention is to afford
strong bonding between a galvanized steel sheet and a metal alloy
or FRP by way of an adhesive.
[0013] New NMT
[0014] The inventors identified conditions under which injection
bonding is possible without chemical adsorption of amine compounds
onto the surface of a metal alloy, i.e. without resorting to the
aid from a special exothermic reaction or from any chemical
reaction. Specifically, the inventors identified conditions that
enable strong bonding, by injection bonding, between thermoplastic
resins and metal alloys other than aluminum alloys. The injection
bonding mechanism based on the above conditions was termed "new NMT
(acronym of nano-molding technology)" by the inventors.
[0015] These inventions, all of which stem from the same inventors,
rely on bonding principles that derive from a comparatively simple
bonding theory. The inventors have called "NMT" (acronym of
Nano-molding technology) the bonding theory relating to aluminum
alloys, and "new NMT" the theory relating to injection bonding of
all metal alloys. The theoretical hypothesis "new NMT", which has a
wider scope, posits the following. Both the metal alloy and the
resin must meet several conditions in order to achieve injection
bonding with powerful bonding strength. In the first place, the
metal alloy must meet three conditions, as follows.
[0016] Conditions Applying to the Metal Alloy Under New NMT
[0017] In the first condition, the chemically etched metal alloy
has a rough surface having a texture of a period of 1 to 10 .mu.m
and a profile height difference of about half the period, i.e. 0.5
to 5 .mu.m. Causing such rough surface to accurately cover the
entire surface is difficult to achieve in practice owing to the
variability inherent to changeable chemical reactions. In concrete
terms, the above-mentioned roughness conditions are found to be
essentially met when the rough surface exhibits a texture of
irregular period from 0.2 to 20 .mu.m, and a roughness curve having
a maximum height difference ranging from 0.2 to 5 .mu.m, as
observed using a profilometer, or exhibits an average period, i.e.
peak-valley average spacing (RSm) of 0.8 to 10 .mu.m and a maximum
height roughness (Rz) of 0.2 to 5 .mu.m, according to JIS Standards
(JIS B 0601:2001), based on scanning analysis using the latest
dynamic-mode scanning probe microscopes. For the inventors, the
ideal period of the irregular shapes of the ideal rough surface
ranges substantially from 1 to 10 .mu.m, as described above. This
range constitutes a "surface of micron-scale roughness" in an
easily understandable definition.
[0018] The second condition prescribes that the metal alloy surface
having the above micron-scale roughness should further have
ultra-fine irregularities of 5 nm or higher. In other words, the
metal surface must exhibit a rough surface as evidenced under the
microscope. To satisfy the above condition, the metal alloy surface
must be subjected to fine etching, an oxidation treatment, a
conversion treatment or the like, to form ultra-fine
irregularities, having a period of 5 to 500 nm, preferably from 10
to 300 nm, and more preferably from 30 to 100 nm, on the inner wall
faces of the recesses that constitute the above-described
micron-scale roughness.
[0019] Penetration by the resin fraction becomes clearly difficult
when the period of the ultra-fine irregularities is 10 nm or less.
In such cases, the profile height difference becomes usually
smaller as well, so that a smooth surface can be viewed from the
resin side. The spike function is lost as a result. When the period
is about 300 to 500 nm, or larger than that (in which case the
diameter and/or period of the recesses that make up the
micron-scale roughness is estimated to be about 10 .mu.m), the
number of spikes in the micron-scale recesses drops dramatically,
and the effect of the spikes is not readily brought out. Therefore,
the period of the ultra-fine irregularities must in principle lie
within 10 to 300 nm. Depending on the shape of the ultra-fine
irregularities, however, the resin may penetrate into the
ultra-fine irregularities even when these have a period of 5 nm to
10 nm. A case in point is, for instance, a tangle of rod-like
crystals having diameters from 5 to 10 nm. In some cases, the shape
of the ultra-fine irregularities elicits readily an anchor effect
even for a period of 300 nm to 500 nm. Another case in point is,
for instance, a morphology similar to a perlite structure
comprising an endless succession of steps having a height and
length of several hundred nm to 500 nm, and a width of several
hundred nm to several thousand nm. The required period of the
ultra-fine irregularities is thus set to 5 nm to 500 nm, to account
for cases such as the above.
[0020] Conventionally, the first condition prescribed an RSm range
of 1 to 10 .mu.m and an Rz range of 0.5 to 5 .mu.m. However, high
bonding strength can be preserved if the texture period of the
ultra-fine irregularities lies within a particularly preferred
range (about 30 to 100 nm), even if RSm ranges from 0.8 to 1 .mu.m
and Rz ranges from 0.2 to 0.5 .mu.m. Therefore, the RSm range was
somewhat expanded to encompass lower values. Specifically, RSm was
set to 0.8 to 10 .mu.m and Rz to 0.2 to 5 .mu.m.
[0021] According to the third condition, the surface layer of the
metal alloy is a ceramic substance. Specifically, the surface layer
of a metal alloy having intrinsically corrosion resistance should
have a metal oxide layer of a thickness equal to or greater than
the thickness of the native oxide layer. In metal alloys having
comparatively low corrosion resistance (for instance, magnesium
alloys or ordinary steel materials), the surface layer is subjected
to a conversion treatment to form a thin layer of a metal oxide or
a metal phosphate, to satisfy the third condition.
[0022] The above features are schematically illustrated in FIG. 12.
Recesses (C) that constitute the micron-scale roughness are formed
on the surface of a metal alloy 70. Further, ultra-fine
irregularities (A) are formed in the inner walls of the recesses.
The surface layer is a ceramic substance layer 71. Part of the
cured adhesive layer 72 penetrates into the ultra-fine
irregularities. In a simple approximation, the liquid resin
composition infiltrates into the metal alloy surface, and is cured
after doing so, whereupon the metal alloy and the cured resin
composition become bonded to each other very strongly.
[0023] Resin Conditions According to New NMT
[0024] The conditions that apply to the resin are explained next.
As the resin there can be used a hard, highly-crystalline
thermoplastic resin, having a slow crystallization rate upon rapid
cooling, for instance through compounding with other polymers that
are appropriate for the resin. In practice there can be used a
resin composition wherein a crystalline hard resin such as PBT or
PPS is compounded with, for instance, appropriate other polymers
and glass fibers.
[0025] Injection Bonding According to New NMT
[0026] Injection bonding can take place using an ordinary injection
molding machine and an injection mold, and employing the
above-described metal alloy and resin. This process is described
according to the above "new NMT". The injected molten resin is led
into a mold at a temperature lower than the melting point by about
150.degree. C. The molten resin is found to cool within flow
channels down to a temperature even at or below the melting point.
That is, no immediate change to solid occurs in zero time, through
crystallization when the molten crystalline resin is cooled
rapidly, even at or below the melting point of the molten resin. In
effect, the molten resin persists in a molten, supercooled state
for a very short time also at or below the melting point. The
duration of this supercooling appears to have been successfully
prolonged somewhat in PBT and PPS through special compounding, as
described above. This feature can be exploited to allow
micro-crystals to penetrate into the recesses of the metal surface
having micron-scale roughness before the abrupt rise in viscosity
that is brought about by generation of large amounts of such
micro-crystals. Cooling is continued after infiltration. As a
result, the number of micro-crystals increases dramatically,
causing viscosity to rise abruptly. Whether the resin can penetrate
or not all the way into the recesses is determined by the size and
shape of the recesses.
[0027] Results of experiments by the inventors indicate that,
irrespective of the type of metal, the micro-crystals can penetrate
all the way into recesses having a diameter of 1 to 10 .mu.m,
according to, the above micron-scale roughness, and having a depth
that is about half the period. When the inner wall faces of the
recesses have a rough surface as evidenced in microscopic
observations, as per the second condition above, the resin
penetrates partly also into the crevices of these fine
irregularities. As a result, the resin catches onto the
irregularities and is difficult to pull away when a pulling force
acts from the resin side. Such a rough surface exhibits high
hardness and affords an effective spike-like catching between the
resin and the recesses in the ultra-fine irregularities, when the
surface is covered with a metal oxide or metal phosphate as per the
third condition.
[0028] Specific examples of the above follow next. In the case of
magnesium alloys, for instance, the corrosion resistance of a
magnesium alloy covered with an unmodified native oxide layer is
low. Therefore, the magnesium alloy is subjected to a conversion
treatment to form a surface layer of a metal oxide, a metal
carbonate or a metal phosphate, and allow thereby the surface to be
covered by a high-hardness ceramic substance. When a magnesium
alloy having undergone such a surface treatment is injected into an
injection mold, the mold and the inserted magnesium alloy are kept
at a temperature lower than the melting point of the injected resin
by 100.degree. C. or more. As a result, the injected resin cools
rapidly upon entering passages inside the mold, so that there is a
high likelihood that the resin is at or below the melting point by
the time it comes near the magnesium alloy.
[0029] When the diameter of the recesses of the magnesium alloy
surface is comparatively large, of about 1 to 10 .mu.m, the resin
can infiltrate within a time window that is limited by the
generation of micro-crystals by supercooling. The resin can
penetrate into the above recesses also if the number density of the
formed polymer micro-crystal clusters is still small, since
estimates from molecular models suggest that the size of these
micro-crystals, i.e. micro-crystals of the shape they had at the
time where some ordered state in molecular chains arises from a
disordered motion of the molecular chains, is of several nm to 10
nm. Therefore, although micro-crystals are not found to be able to
get easily into ultra-fine irregularities having a diameter of 10
nm, the front of the resin stream can nevertheless penetrate
somewhat into ultra-fine irregularities having a period of several
tens of nm. Micro-crystals form simultaneously in large numbers,
though, and hence viscosity of the resin flow rises abruptly at the
leading front of the injected resin and at sites of contact with
the mold metal surface. When observed under electron microscopy,
the surface of the magnesium alloy exhibits an ultra-fine irregular
surface having a period of 10 to 50 nm. The front of the resin flow
can enter into ultra-fine irregularities having approximately such
a period, before the abrupt rise in viscosity.
[0030] Fairly strong bonding strength has been achieved when a PPS
resin (or PPS resin compound obtained through lowering of the
crystallization rate of PPS molecules upon rapid cooling) is
injection-bonded onto the surface of a metal alloy such as a copper
alloy, a titanium alloy or a steel material that has been oxidized
or subjected to a conversion treatment, and the surface layer
exhibits as a result micro-crystal clusters or an amorphous layer
of a metal oxide or the like.
[0031] Although bonding per se is determined by the resin component
and the metal alloy surface, adding reinforcing fibers or an
inorganic filler to the resin composition allows bringing the
coefficient of linear expansion of the resin as a whole closer to
that of the metal alloy. This allows preserving easily bonding
strength after bonding. Composites obtained through injection
bonding of a PBT or PPS resin with a magnesium alloy, copper alloy,
titanium alloy, steel material or the like, in accordance with the
above hypothesis by the inventors, are strong integrated products,
having a shear rupture strength of 20 to 30 MPa (about 200 to 300
kgF/cm.sup.2) or more and a tensile rupture strength of 30 to 40
MPa (about 300 to 400 kgF/cm.sup.2) or more.
[0032] Herein, the magnitude of the viscosity of the liquid resin
in the environment of the latter (pressure, temperature) is a
factor that determines the extent to which the resin can penetrate
into the crevices of the ultra-fine irregularities. In this
context, the "new NMT" theory can be applied to instances of
adhesion using one-liquid thermosetting adhesive, where it is
possible to achieve strong adhesive strength. However, whether or
not the anticipated effect is elicited thereby depends
significantly on the liquid viscosity prior to curing.
[0033] Other technologies involve inserting a metal part into the
mold of an injection molding machine, where the part is integrated
with a thermoplastic resin material that is injected into the mold
(for instance, see Patent document 4). The technology set forth in
Patent document 4 is not a technology relating to "injection
bonding" of the present invention, but an injection molding
technology that exploits the relationship between the molding
shrinkage of a resin and the coefficient of linear expansion of a
metal. As disclosed in the above Patent document, a molded article
comprising a metallic rod-like material having a resin portion
running through the former is obtained through injection molding of
a thermoplastic resin around the metallic rod-like material. The
molded article is removed then from the mold and is cooled,
whereupon the metal-made rod part becomes gripped by the resin
molded article. The coefficient of linear expansion of the metal
ranges at most from 1.7 to 2.5.times.10.sup.5.degree. C..sup.-1 for
aluminum alloys, magnesium alloys and copper alloys, and thus the
degree of shrinkage of the metal upon demolding and cooling down to
room temperature does not exceed the coefficient of linear
expansion times about 100.degree. C., i.e. a shrinkage of 0.2 to
0.3%. By contrast, the mold shrinkage of the resin is of about 1%
for PPS and 0.5% for PPS containing glass fibers. Even in the case
of a resin containing a filler, the shrinkage of the resin portion
after injection molding is necessarily far greater than that of the
metal part. Therefore, injection molding of a shaped article using
a metal part in the middle, as an insert, such that the metal part
runs through the resin portion, has the effect of tightening the
whole on account of the molding shrinkage of the resin portion. As
a result there can be manufactured an integrated product from which
the metal part is difficult to pull out.
[0034] Several methods are known in which an integrated product of
a metal and a resin are manufactured by taking advantage of such
gripping. Knobs on fuel oil stoves, for example, are manufactured
in accordance with such a method, which involves inserting a thick
iron needle, having a diameter of about 2 mm, into an injection
mold, and injection of a heat-resistant resin or the like into the
mold. In this method, jagged bumps (resulting from knurling) are
formed on the needle, so that the resin does not move. Patent
document 4 is characterized in that surface morphology is smoothed,
and irregularities made finer, by changing the texturing process
from a physical process to a chemical process, and in that the grip
effect is improved by using a resin that is both hard and
crystalline. Patent document 4 is found to elicit a significant
improving effect as regards air-tightness, in that leakage of
generated gas along the metal rods is significantly curbed.
However, virtually no improving effect on adherence can be
appreciated (paragraph 0010). Such being the case, new NMT affords
the distinctive advantage of adherence, i.e. of allowing strong
bonding between a metal alloy and a resin, vis-a-vis Patent
document 4.
[0035] Specifically, new NMT requires no gripping by the resin at
all. A powerful force is needed to split a composite of a metal
alloy and a resin molded article obtained on the basis of new NMT.
Another major characterizing feature of the present invention is
the use of a high-hardness crystalline resin composition that
crystallizes and solidifies over a long supercooling time during
rapid cooling. Indeed, maintaining the bonded state between metal
alloy and thermoplastic resin stably over long periods of time
requires that the numerical values of the coefficient of linear
expansion of the metal alloy and of the thermoplastic resin should
be similar. The coefficient of linear expansion of the
thermoplastic resin composition can be lowered significantly by
incorporating into the resin a substantial amount of a filler, i.e.
reinforcing fibers such as glass fibers or carbon fibers.
[0036] NAT (Adhesive Bonding)
[0037] Specifically, the inventors speculated that the "new NMT"
theoretical hypothesis can be applied also to adhesive bonding, and
checked whether high-strength joining can be achieved based on a
similar theory. That is, the inventors set out to ascertain whether
bonded bodies having higher adhesive strength can be obtained by
exploiting the surface structure of the metal alloy and by using
commercially available general-purpose one-liquid epoxy
adhesives.
[0038] The procedure in an experimental method for bonding using
adhesives is as follows. On the basis of "new NMT" there is firstly
prepared a metal alloy (metal alloy satisfying the above three
conditions) having a surface identical to the surface in the
above-described injection bonding experiments. A liquid one-liquid
epoxy adhesive is coated onto the surface of the metal alloy. The
metal alloy is placed once under vacuum, after which the pressure
is reverted to normal pressure. As a result, the adhesive
penetrates into the ultra-fine irregularities on the surface of the
metal alloy. In other words, the adhesive impregnates thoroughly
the metal alloy surface. An adherend is affixed then onto the
predetermined area, and the adhesive is cured through heating.
[0039] Herein, the epoxy adhesive can penetrate into the recesses
of the micron-scale roughness (recesses of the irregularities
according to the first condition) on the surface of the metal alloy
by virtue of being in the form of a liquid, although somewhat
viscous. The epoxy adhesive that has penetrated into the recesses
is then cured within the recesses by heating. Actually, the inner
wall surface of the recesses is a surface having ultra-fine
irregularities (second condition above), and these ultra-fine
irregularities are covered by a high-hardness thin film of a
ceramic substance (third condition above). Therefore, the epoxy
resin, which solidifies in the recesses into which it has
penetrated, is caught by the spiky ultra-fine irregularities, and
becomes hard to pull out.
[0040] The inventors have shown that "new NMT" affords
high-strength joining between metal alloys, and between a metal
alloy and CFRP (acronym of carbon fiber-reinforced plastic), using
one-liquid epoxy adhesives. As an example, A7075 aluminum alloys
bonded to each other by way of a commercially-available one-liquid
epoxy adhesive yield bonded bodies that exhibit substantial shear
rupture strength, up to 70 MPa, and tensile rupture strength.
[0041] The inventors found such high-strength adhesive bonding
first in aluminum alloys, and then in magnesium alloys, copper
alloys, titanium alloy, stainless steel, and ordinary steel
materials. By controlling the surface morphology of the adherend in
the form of a metal alloy, the inventors achieved unprecedented
strong joining in all the above metal alloys. The above instances
of adhesive bonding relying on "new NMT" have been generically
termed "NAT (acronym of nano-adhesion technology)" by the
inventors.
[0042] "New NMT" can also be used in bonding technologies different
from injection bonding. Specifically, a resin molded article is
manufactured firstly by injection molding or the like using a
starting material in the form of a resin composition having a
high-hardness crystalline resin as a main component. In parallel, a
metal alloy piece that satisfies the above first condition to third
condition according to "new NMT" is prepared and is heated in a hot
plate or the like. The heated metal alloy piece is pushed against
the resin molded article. If the temperature of the metal alloy
piece is higher than the melting point of the resin composition,
the latter melts at the contact surface. The whole is left to stand
in that state, and the temperature at the contact surface between
the metal alloy and the resin molded article drops below the
melting point of the resin over a few seconds to ten or more
seconds. Thereupon, part of the molten resin penetrates into the
ultra-fine irregularities on the surface of the metal alloy, and
crystallizes and solidifies thereafter.
[0043] Using such a method does away with the need of slowing down
the crystallization and solidification rate, upon rapid cooling,
through special compounding or the like, and thus the conditions
required from the resin composition are less strict. The pressure
during infiltration, unlike that in injection bonding, is extremely
low, of about 1 atmosphere, even upon evacuation during melting and
subsequent return to normal pressure. This cannot be regarded as
the optimal condition for eliciting bonding strength, but a
practicable bonding strength is achieved nevertheless. The above
constitutes a method for press-fusion bonding a molded article
using a highly crystalline thermoplastic resin.
[0044] The inventors performed a surface treatment, in accordance
with "new NMT", on cold rolled steel materials and hot rolled steel
materials, which are the most common steel materials for
structures, followed by injection bonding of a thermoplastic resin
composition to the above steels. Also, the inventors performed a
surface treatment, in accordance with "new NMT", on cold rolled
steel materials and hot rolled steel materials, followed by joining
and bonding to CFRP. The composites thus obtained exhibited
unprecedented high bonding strength.
[0045] Galvanized steel sheets are widely used as an outdoor steel
material for buildings in the field of construction materials,
thanks to their high versatility. In particular, there is a strong
demand for composite articles in which galvanized steel sheets and
resin molded articles are strongly bonded to each other. Such being
the case, the inventors have conducted research and development on
whether galvanized steel sheets as well can be injection-bonded on
the basis of "new NMT" using PBT or PPS resins. The inventors have
also studied whether galvanized steel sheets and resin molded
articles, galvanized steel sheets and CFRPs, and galvanized sheets
and metal alloys can be strongly joined and bonded on the basis of
"NAT". Results have shown that a composite can be obtained wherein
a galvanized steel sheet and a resin molded article are strongly
integrated, by injection bonding, by performing a surface treatment
(to form a surface that satisfies the above-described first
condition to third condition) on a galvanized steel sheet, in
accordance with "new NMT", and by injecting a thermoplastic resin
composition onto the galvanized steel sheet. Results have also
shown that galvanized steel sheets and resin molded articles,
galvanized steel sheets and CFRPs, galvanized steel sheets and
GRRPs, and galvanized steel sheets and metal alloys can be strongly
joined and bonded on the basis of "NAT". Press-fusion bonding
between galvanized steel sheets and resin molded articles proved
also possible.
[0046] The means used in the present invention are explained in
further detail below.
[0047] 1. Galvanized Steel Sheet The galvanized steel sheet of the
present invention includes hot-dip galvanized steel sheets, alloyed
hot-dip galvanized steel sheets, electro-galvanized steel sheets,
electro-galvanized steel materials such as hot-dip zinc-aluminum
alloy coated steel sheets (for instance, galvalume steel sheets in
the form of hot-dip Zn-55% Al alloy plated steel sheets, or hot-dip
Zn-11% Al-3% Mg alloy plated steel sheets or the like). Most
commercially-supplied galvanized steel sheets are subjected to
various conversion treatments and post-treatments. Specifically,
the above material groups are excellent corrosion resistance steel
materials having an internal protective effect elicited mainly
through oxidation of surface zinc or on account of a carbonate
coating. Even in case of breakage, zinc itself affords a
sacrificial corrosion effect whereby corrosion of the core steel
material is slowed down. The above material groups, however, are
seldom used without further modification, and are often subjected
to a conversion treatment, for instance a chromate treatment or a
non-chromate treatment, or are coated with an organic-matter
coating that contains chromium compounds, so that the galvanized
layer itself is protected. Galvanized steel sheets thus subjected
to a conversion treatment are often oiled, to yield thereby a steel
material having secured lubricity at the time of press working.
Large material manufacturers supply various surface-treated
products depending on the application and on the needs of
secondary-processing users. Also, coating is often carried out by
the galvanized steel sheet manufacturer itself, to manufacture and
market products in the form of precoated steel sheets called color
steel sheets or color galvanized steel sheets.
[0048] The present invention applies to all the above galvanized
steel sheets. Specifically, the present invention applies to all
galvanized steel sheets of the above-described basic materials
(galvanized steel sheets prior to a conversion treatment), to
conversion-treated galvanized steel sheets, and to oiled galvanized
steel sheets of the foregoing. When using a precoated steel sheet
or a galvanized steel sheet coated with a coating that contains
chromium compounds, the coating film must be stripped in some way.
The material after stripping constitutes the material of the
present invention.
[0049] In the below-described examples there was used an oiled and
conversion-treated hot-dip galvanized steel sheet "Z18 (by Nippon
Steel & Sumikin Metal Products)" according to JIS G3302, which
is arguably the most commonly used galvanized steel sheet excluding
precoated steel sheets. The amount of plating of "Z18", according
to JIS, is 120 g/m.sup.2. Most commercially available products
range from "Z12" (plating amount 90 g/m.sup.2) to "Z27" (plating
amount 190 g/m.sup.2). "Z18", having an average plating amount, has
a large market volume of the above steels. Ordinarily, non-oiled
steel materials are used in applications that involve no press
forming, or in press forming applications where the degree of
drawing is low. Other applications include AV products, as well as
electric articles such as copiers, printers and the like, where oil
is best avoided. Oiled products, having an unbroken plating layer
and lubricity during pressing, are used in most applications. Zinc
plated layers are comparatively pliable as a metal, and thus are
not vulnerable to drawing. Therefore, the coating is not adversely
affected, since even in the case of oiled products, the amount of
oil coating is very small, and even in the case of a decorating
process through painting, as a final process, the oil material on
the surface is dissolved by the paint solvent. The present
invention affords a surface treatment that conforms to "new NMT"
and "NAT" simply through chemical treatment of all
commercially-available galvanized steel sheets, whether oiled or
not, or whether a conversion treatment layer is present or not
underneath the oil coating layer.
[0050] 2. Surface Treatment/Overview
[0051] Ordinarily, four fundamental steps, namely a. degreasing, b.
chemical etching, c. fine etching and d. surface hardening are
performed to obtain metal alloys in accordance with the "new NMT"
or the "NAT" theories, i.e. to achieve a surface that satisfies the
above-described conditions (1) to (3). From among the four steps
above, in some instances "a. degreasing" may be omitted, "b.
chemical etching" may double as "c. fine etching", or "b. chemical
etching" may double as "c. fine etching" and "d. surface
hardening", depending on the type of metal alloy used. In other
cases, a conversion treatment performed as "d. surface hardening"
may double as "b. chemical etching" and "c. fine etching". In all
cases, the basic approach of the inventors in the chemical
treatment methods that were practiced involved performing the
specific process "a" to "d" with the intended purpose in mind,
evaluating the obtained results, and omitting a relevant process
when it was found that the process could be effectively
omitted.
[0052] In practice, there are four types of galvanized steel sheets
commercially available in Japan, namely hot-dip galvanized steel
sheets, electro-galvanized steel sheets, zinc-55% aluminum alloy
plated steel sheets (galvalume steel sheets), and zinc-11%
aluminum-3% magnesium alloy plated steel sheets. From among these,
a detailed explanation follows first on a surface treatment method
of oiled chromate-treated hot-dip galvanized steel sheets, which as
described above are the kind of galvanized steel sheet most used by
secondary processing manufacturers.
[0053] The above steel sheets were immersed for a somewhat long
time in an aqueous solution of the degreasing agent at a
particularly high temperature. Thereafter, the sheets were rinsed
with water and dried, to thereby eliminate the surface layer, in
the form of an oil layer or a grease layer, that was originally
observable by electron microscopy. As a result there appeared a
surface layer made up of a new ultra-fine irregular surface. XPS
analysis revealed the presence of chromium in this new surface
layer. This indicated that the surface layer derived from the
chromate treatment. Specifically, the surface is covered by a thin
layer of a hard phase. With the oily layer is removed, the surface
of the hot-dip galvanized steel sheet exhibits micron-scale
roughness having a peak-valley average spacing (RSm) of 0.8 to 10
.mu.m and a maximum height roughness (Rz) of 0.2 to 5 .mu.m.
Therefore, strong integration with an adherend can be achieved in
that state, without further modification, through injection bonding
or adhesive bonding. In the shortest treatment performed by the
inventors, "a. degreasing" doubled as the other "b. chemical
etching", "c. fine etching" and "d. surface hardening".
[0054] This case corresponds obviously to an instance where the
conversion treatment (herein chromate treatment) performed by the
material manufacturer on the hot-dip galvanized steel sheets was
appropriate for the purposes of the present invention. In this case
as well, the roughness level of the original hot-dip galvanized
layer falls accidentally within the range mandated by the present
invention. The degreasing agent used by the inventors in the "a.
degreasing" treatment has the effect of dissolving and removing the
oil but without negatively affecting the chromate layer. In such a
degreasing step there can be used a degreasing agent in the form of
commercially-available industrial degreasing agents for steel
materials or aluminum, but degreasing agents for aluminum are
particularly preferred. As regards the way in which the degreasing
agent is used, the aqueous solution of the degreasing agent has
preferably a high liquid temperature, specifically 70.degree. C. or
higher, in terms of removing strongly adhered greasy oil and/or
special organic polymer materials for lubrication. The immersion
time is preferably 5 minutes or longer, for instance of about 5 to
10 minutes. The inventors essayed various liquid temperatures and
immersion times through trial-and-error, and observed the state of
the surface of the galvanized steel sheets after degreasing, to
establish the above conditions. The immersion time can be shortened
by performing degreasing under application of ultrasounds from an
ultrasound probe provided in the degreasing bath.
[0055] The degreasing treatment presents no particular
difficulties, regardless of the conversion treatment carried out by
the manufacturer of the steel sheet. When the above degreasing
alone does not yield a surface that conforms to "new NMT" or "NAT",
degreasing is followed by immersion in an acidic aqueous solution,
for instance a dilute aqueous solution of sulfuric acid. The
conversion treatment layer is stripped as a result, whereupon
chemical etching of the galvanized layer can proceed. Micron-scale
roughness can be obtained therefore by adjusting the etching level
during chemical etching. The ultra-fine irregular surface can be
formed next through a light chromate treatment, a zinc phosphate
conversion treatment or a zinc calcium phosphate conversion
treatment. Specifically, "b. chemical etching" and "d. surface
hardening" follow "a. degreasing". In this case, "d. surface
hardening" is the conversion treatment itself but doubles also as
"c. fine etching".
[0056] A series of experiments based on the above approach showed
that further steps could be omitted, and that the conversion
treatment in the form of the "d. surface hardening" step can double
as "b. chemical etching". Specifically, the treatment solutions for
all the conversion treatments, namely the chromate conversion
treatment, the zinc phosphate conversion treatment, and the zinc
calcium phosphate conversion treatment, are acidic aqueous
solutions having a pH ranging from 1 to 3. The treatment solutions
that are adopted from among the foregoing are those that, after a
degreasing step and subsequent immersion of the chromate-treated
galvanized steel sheet, release hydrogen and elicit observable
corrosion over the entire surface. Therefore, it was judged that
the above process can double also as "b. chemical etching" by
adjusting immersion conditions and so forth. In fact, judicious
selection of the conditions allow completing all the processes by
performing simply the "a. degreasing" and "d. surface hardening"
treatments.
[0057] In zinc-aluminum alloy coated steel sheets, however, the
above abbreviated treatments often fail to yield the surface
anticipated by "new NMT" and "NAT". In such cases, the "b. chemical
etching" step includes preferably an additional step of etching the
zinc aluminum alloy phase through immersion in an acidic aqueous
solution having a pH from 1 to 3, specifically a dilute aqueous
solution of an acid whose waste can be disposed of easily and
inexpensively, for instance sulfuric acid or hydrochloric acid.
Specifically, galvalume steel sheets require the steps of "a.
degreasing", "b. chemical etching" and "d. surface hardening". In
galvalume steel sheets as well, "d. surface hardening" is a
so-called conversion treatment. This conversion treatment gives
rise to an ultra-fine irregular surface, and hence "c. fine
etching" can be omitted.
[0058] A specific conversion treatment method as the "d. surface
hardening" step is explained below. Although it has been indicated
that a chromate treatment, a zinc phosphate treatment or a zinc
calcium phosphate treatment can be used, the required end result
mandates that the zinc phase should be covered with a thin film of
a ceramic substance and should have an ultra-fine irregular
surface, and that there must be sufficiently strong bonding
strength between the thin film layer and the zinc phase. The
inventors found that as such a conversion treatment there can be
used at least a chromate treatment, a zinc phosphate treatment, or
a zinc calcium phosphate treatment. Other conversion treatment
methods may also be used, provided that the above requirements are
met.
[0059] Each conversion treatment is described in detail below.
Numerous known methods employ chromate treatment solutions.
Particularly preferred herein is an acidic aqueous solution of
phosphoric acid containing trivalent chromium and hexavalent
chromium. A preferred surface is achieved through immersion at low
temperature when a small amount of nickel ions is also present, for
unclear reasons that may have to do with the catalytic action of
the nickel ions in the formation of the chromate layer. More
specifically, there is preferably used an aqueous solution, at
about 40.degree. C., containing 1 to 1.5% of chromium nitrate,
about 0.3% of anhydrous chromic acid, 1.5 to 2% of phosphoric acid
and about 0.01 to 0.05% of basic nickel carbonate.
[0060] In the zinc phosphate conversion treatment solution,
preferably, a small amount of additional nickel ions is also
present together with phosphoric acid and divalent zinc.
Fluorosilicate ions are also preferably present, as they are
effective in eliciting better performance. More specifically, there
is preferably used an aqueous solution, at 50 to 60.degree. C.,
that contains 1 to 1.5% of phosphoric acid, and about 0.2% each of
zinc oxide, basic nickel carbonate, and sodium fluorosilicate.
[0061] In the zinc calcium phosphate conversion treatment solution,
preferably, a small amount of additional nickel ions is also
present together with phosphoric acid, divalent zinc and calcium.
Zinc calcium phosphate conversion treatment solutions that are
superior conversion treatment solutions for steel materials are
ineffectual unless at high temperature, ordinarily at 80.degree. C.
or higher, but when used in the present invention, however,
sufficiently good effects were elicited at 60 to 65.degree. C.
Micrographs obtained by electron microscopy are described in the
experimental examples set forth below. As a concrete solution
composition there is preferably used an aqueous solution containing
1 to 1.5% of phosphoric acid, and about 0.2% each of zinc oxide,
basic nickel carbonate and calcium nitrate.
[0062] The "new NMT" and "NAT" theories mandate that, ultimately,
the scanning results of the rough surface under a scanning probe
microscope should reveal a surface having RSm of 0.8 to 10 .mu.m
and Rz of 0.2 to 5 .mu.m, and covered by an ultra-fine irregular
surface having a period of 5 to 500 nm, more preferably an
ultra-fine irregular surface having a period of to 100 nm. When RSm
is smaller than about 0.8 .mu.m, the texture period is too small
and thus the resin fraction is less likely to penetrate thoroughly,
whether in injection bonding or adhesive bonding. By contrast,
bonding strength drops significantly when RSm is 10 .mu.m or
greater. In this latter case, the recess period and pore diameter
are excessively large, and the absolute number of recesses
decreases. This results in a dramatically weaker anchor effect and,
accordingly, lower bonding strength.
[0063] The reason for setting the numerical value of Rz to be about
half RSm is that the resins used by the inventors for injection
bonding, namely improved PBT-based resin compositions, PPS resin
compositions and aromatic polyamide resin compositions can
penetrate down to the bottom of the recesses when the latter have a
depth of about half the texture period. The same is true of the
liquid one-liquid adhesives that can penetrate under pressure
differences up to about 1 atmosphere. If Rz is larger, i.e. when
the bottom of the irregularities is deeper, the above-mentioned
resins do not intrude all the way down, and there arise voids, at
the bottom of the micron-scale recesses, that remain after
completion of the bonding process and that constitute the phase
most susceptible to breakage. High bonding strength cannot be
achieved in that case. An excessive small Rz shifts most of the
burden of preserving bonding strength to the ultra-fine
irregularities, and results ultimately in a drop of bonding
strength.
[0064] The results of observations of the surface obtained by
subjecting the above-described oiled and chromate-treated hot-dip
galvanized steel sheet "Z18" to a high-temperature degreasing step,
upon ten measurements of roughness using a scanning probe
microscope, revealed an RSm ranging from 0.8 to 3 .mu.m, and Rz=0.3
to 1 .mu.m. The Rz value is rather small, and hence irregularities
slightly shallow, from the viewpoint of the rough surface
postulated by the "new NMT" and "NAT" general theories. The texture
period of ultra-fine irregularities under electron microscopy
ranged from 80 to 150 nm, and was mostly of about 100 nm, which
corresponded to the most preferred period for ultra-fine
irregularities. Thus, the shape of the ultra-fine irregularities
was particularly appropriate, and hence the shape of the ultra-fine
irregularities matches the conditions of "new NMT" and "NAT" when
RSm ranges from 0.8 .mu.m to 10 .mu.m and Rz ranges from 0.2 to 5
.mu.m, as described above. Both RSm (0.8 to 3 .mu.m) and Rz (0.3 to
1 .mu.m) thus measured meet the conditions of "new NMT" and "NAT".
The appearance of the ultra-fine irregularities resulting from the
conversion treatment performed by the inventors is described in the
examples set forth below. In all cases, the period of the
ultra-fine irregularities fell within the preferred range of 10 to
300 nm.
[0065] 3. Thermoplastic Resin Composition for Injection Bonding
[0066] The resin composition is directly bonded to the galvanized
steel sheet by injection molding. The resin composition denotes
herein a first resin composition having PBT, which is a crystalline
resin, as a main component, a second resin composition having PPS
as a main component, or a third resin composition having an
aromatic polyamide as a main component. The resin fraction of the
first resin composition is a resin composition having PBT as a main
component and polyethylene terephthalate (hereafter, "PET") and/or
a polyolefin resin as an auxiliary component. The resin fraction of
the second resin composition is a resin composition having PPS as a
main component and a polyolefin resin as an auxiliary component.
The resin fraction of the third resin composition is a resin
composition having an aromatic polyamide as a main component and an
aliphatic polyamide as an auxiliary component.
[0067] In the first resin composition, PBT may range from 70 to 97
wt %, and PET and/or a polyolefin resin from 3 to 30 wt %. In the
second resin composition, PPS may range from 70 to 97 wt %, and the
polyolefin resin from 3 to 30 wt %. In the third resin composition,
the aromatic polyamide may range from 50 to 100 wt %, and the
aliphatic polyamide from 0 to 50 wt %. Injection bonding strength
drops significantly outside the above ranges.
[0068] Preferably, the resin composition is PPS or PBT comprising
20 to 60 wt %, relative to the entire composition, of one or more
types of filler selected from among glass fibers, carbon fibers,
aramid fibers and other reinforcing fibers, calcium carbonate,
magnesium carbonate, silica, talc, clay and glass powder. The
presence of the above fillers causes the coefficient of linear
expansion of the resin molded article to range from about
2.0.times.10.sup.-5.degree. C..sup.-1 to
3.0.times.10.sup.-5.degree. C..sup.-1, close to the coefficient of
linear expansion of the metal alloy. As a result, internal strain
generated at the joining faces during temperature changes can be
kept at a low level.
[0069] 4. Composite Manufacture/Injection Bonding Using a
Thermoplastic Resin
[0070] The composite manufacturing method according to the present
invention is an injection molding method wherein a metal alloy is
inserted into a mold, as follows. To manufacture a composite, an
injection mold is prepared, and a shape comprising a galvanized
steel sheet is inserted into the mold. The mold is closed, and the
improved PBT, improved PPS or improved aromatic polyamide
thermoplastic resin composition is injected. After solidification,
the mold is opened and the resulting composite is demolded.
[0071] Injection conditions are explained next. Preferably, the
mold temperature is 100.degree. C. or higher for PBT or PPS resins,
since that temperature affords superior composite productivity with
little impact on resulting strength, in particular after
solidification. More preferably, the mold temperature is
120.degree. C. or higher. The injection temperature, injection
pressure and injection rate are not particularly different from
those of ordinary injection molding. If anything, the injection
pressure and the injection rate are preferably rather high.
[0072] 5. Composite Manufacture/Conversion Treatment of a Metal
Resin Integrated Product
[0073] The galvanized steel sheet surface-treated as described
above exhibits a thinner plating layer as compared to the sheet
before the surface treatment. A conversion coating layer is formed
on the plating layer. In injection bonding through insertion of
such a steel sheet into an injection mold, the steel sheet is often
bent by being squeezed in the mold. In such instances, the
conversion coating layer may break, or the plating layer may be
stretched and further thinned out. Therefore, the composite
obtained by injection bonding is preferably subjected again to a
conversion treatment after integration. Bonding strength is seldom
impaired if the composite is rapidly subjected to the repeated
conversion treatment and is dried as quickly as possible.
[0074] 6. Thermoplastic Resin Composition for Press-Fusion
Bonding
[0075] The resin composition used for press-fusion bonding may be a
resin composition having a hard, highly crystalline resin as a main
component. In press-fusion bonding according to "new NMT", the
resin used can be PBT, PPS, an aromatic polyamide, an aliphatic
polyamide, a liquid crystal polymer, polyether ether ketone
(hereafter, "PEEK") or the like. The melting point of PEEK is
excessively high, of about 400.degree. C., and hence and
undesirable for press-fusion bonding of galvanized steel sheets,
since the melting point of PEEK is close to that of zinc. As the
above-described thermoplastic resin for injection bonding there can
be used, needless to say, the improved PBT, PPS or aromatic
polyamide resins employed for injection bonding. In short, there
can be used a hard, highly crystalline resin from among a broader
range of resins than the above-described thermoplastic resin for
injection bonding. Particularly preferred are, for instance, PBT,
PPS and polyamide resins, since they have not too high a melting
point.
[0076] A resin composition having the above resins as a resin
fraction may comprise 20 to 60 wt %, relative to the entire
composition, of one or more types of filler selected from among
glass fibers, carbon fibers, aramid fibers and other reinforcing
fibers, calcium carbonate, magnesium carbonate, silica, talc, clay
and glass powder. The filler may take up 0 to 50% of the liquid
crystal polymer. The presence of the above fillers has the effect
of lowering the coefficient of linear expansion of the resin molded
article.
[0077] 7. Composite Manufacture/Press-Fusion Bonding Using a
Thermoplastic Resin
[0078] The resin fraction of the resin composition used in a
composite manufacturing method relying on press-fusion bonding is
preferably a hard, highly crystalline resin, specifically PBT, PPS,
an aromatic polyamide, an aliphatic polyamide, a liquid crystal
polymer or the like. Needless to say, improved PBT, improved PPS
and improved aromatic polyamide resin compositions that can be
suitably used in injection bonding fall also within this category
and are thus preferably used. To manufacture the resin molded
article, the glass fibers and other fillers are compounded and
blended into the resin composition, and the resulting starting
material blend is injected into an injection molding machine.
[0079] Next, a galvanized steel sheet having been surface-treated
as described above is heated by means of, for instance, a hot
plate, a hot-air dryer or the like, to a temperature even at or
lownot lower than the melting point of the resin composition that
is to be bonded. The above-described resin molded article is then
pressed against the surface of the heated steel sheet. The feature
"not lower than the melting point" denotes herein heating to a
temperature higher than the melting point by about several tens of
.degree. C. and that enables the below-described operations. Zinc
has a low melting point, of about 400.degree. C. When using zinc as
a metal, thus, it is preferable not to employ high-melting point
polymers such as PEEK or the like. Instead, there are preferably
used resins that restrict heating during the heating process up to
about 300.degree. C.
[0080] A preferred operation procedure is outlined below. Firstly,
the surface-treated galvanized steel sheet is heated up to a
predetermined temperature. The heated steel sheet is then
temporarily transferred onto a heat-insulating plate, and the
prepared resin molded article is pressed against the steel sheet
thus disposed. The bottom face of the pressed resin molded article
melts, and the heat dissipates thereafter, to elicit
crystallization and solidification once more. During the above
process, the molten resin gets into the recesses, and into the
ultra-fine irregularities, that make up the micron-scale roughness
on the steel sheet surface. Once the molten resin has penetrated,
it is cooled and solidified once more, to bring bonding about. To
achieve good bonding strength reproducibility, the whole is placed
in vacuum and is reverted thereafter to normal pressure, over a few
seconds to ten or more seconds while the resin is still in a molten
state. To that end, there is prepared a jig appropriate for
press-fusion bonding, and the jig is combined with a vacuum pump.
Press-fusion bonding can be performed thereby in a suitable manner
with good reproducibility. An example of press-fusion bonding is
set forth in the experimental examples.
[0081] 8. One-Liquid Thermosetting Adhesive
[0082] According to the "NAT" theory, bonding is preferably
elicited by a thermosetting adhesive that is liquid when applied,
and that has few macromolecules (gelling molecules). Specifically,
the thermosetting adhesive must penetrate into recesses having a
period of several .mu.m on the surface of a metal alloy (zinc
plated steel material), and must penetrate also into the crevices
of ultra-fine irregularities, having a period of several tens of
nm, that are present within the recesses. Therefore, the viscosity
of the liquid must be at most no greater than 20 Pas, preferably no
greater than about ten or more Pas, during the cycles of
depressurization/return to normal pressure described below.
[0083] The adhesive may be coated onto the surface-treated
galvanized steel sheet, and be then heated at 50 to 80.degree. C.
in a vessel, for instance by being placed in a warmed desiccator.
The operation of depressurization/return to normal pressure is
performed with the steel sheet at the same temperature as that of
the vessel. A paste-like adhesive composition having a viscosity of
several hundred Pas at normal temperature can be used as well, by
being liquefied through heating at 50 to 80.degree. C. However, the
degree of penetration of the adhesive into the crevices of the
ultra-fine irregularities is poor if the adhesive undergoes gelling
or the like under such heating. In case of using such
high-viscosity adhesives, therefore, the gelling and curing
temperature of the adhesive is preferably high.
[0084] The epoxy adhesive is described in further detail next.
Commercially-available one-liquid epoxy adhesives include, for
instance, bisphenol epoxy resins, glycidylamine epoxy resins,
polyfunctional polyphenol-type epoxy resins, alicyclic epoxy resins
and the like, to which amine compounds or dicyandiamide are added
as curing agents. These adhesives can have a comparatively low
viscosity, and are easy to work with, although they exhibit lower
heat resistance than the types described below.
[0085] Many aromatic amine compounds are solid, and thus a mixture
of the foregoing has to be melted once, thereby making manufacture
impossible, when using the aromatic amine compound as a curing
agent. At normal temperature, the mixture has a higher viscosity
and is solid, in the form of a paste. Although the resulting cured
product has characteristically high heat resistance, such a cured
product is difficult to work in the present invention (in terms of
penetrating into the metal alloy surface) after coating, since the
viscosity of the cured product is somewhat too high.
[0086] An acid anhydride can be used as the curing agent. A
thermosetting adhesive formed from an epoxy resin and an acid
anhydride can be preferably used since acid anhydrides can be
produced as low-viscosity liquids. Such adhesives are not
commercially available, since after mixing, the adhesive gels,
albeit slowly, when stored at normal temperature. In terms of
quality assurance, therefore, it is difficult to purchase
commercially available mixtures. When such adhesives are required,
the current ordinary procedure involves procuring the epoxy resin
and the acid anhydride, and compounding these two at the time of
use.
[0087] The mixture is considered to start gelling at around room
temperature, but in fact the curing temperature is often high, of
150.degree. C. or higher, and the polymerization temperature is
likewise high. Accordingly, the epoxy resin (adhesive composition)
having an acid anhydride compounded therein may be stored several
days in a refrigerator without any problems. In this sense,
although an epoxy adhesive having an acid anhydride added thereto
is a two-liquid epoxy adhesive, it is classified essentially as a
one-liquid thermosetting adhesive in the present invention. Such
adhesives can be preferably used, since they yield cured products
having excellent heat resistance.
[0088] (Use of a Two-Liquid Thermosetting Adhesive)
[0089] When using a two-liquid thermosetting adhesive in a metal
alloy surface-treated as described above, bonding strength is
enhanced, although the effect elicited is hard to discern. Most
two-liquid adhesives start gelling from the instant that the curing
agent component is added to, and mixed with, the main liquid. As
gelling proceeds, less resin component penetrates into the crevices
of the (2) ultra-fine irregularities. When a two-liquid adhesive is
used, changes in adhesive strength as time goes by, after mixing
with the curing agent, are a common occurrence. This impairs
stability and reproducibility, and is hence undesirable.
Nevertheless, as mentioned earlier, two-liquid adhesives in the
form of epoxy adhesive using an acid anhydride as a curing agent
are preferably used in case that a certain time elapses until the
onset of gelling and in case that the gelling temperature is high.
Such adhesives can be handled substantially in the same way as
one-liquid adhesives.
[0090] The same is true of phenolic adhesives and unsaturated
polyester adhesives. Phenolic adhesives are commercially available,
but many have added solvent, and as in the case of many epoxy
adhesives, are not solvent-less. However, letting the adhesive
solidify through solvent evaporation shortly after application,
followed by depressurization/return to normal pressure at a
moderate temperature of 50 to 70.degree. C., allows the phenolic
resin remaining after solvent evaporation to melt into a viscous
liquid of about 10 Pas. As a result, the adhesive can penetrate
into the ultra-fine irregularities and drive out the air present in
the latter.
[0091] Although no unsaturated polyester adhesives are commercially
available, there are marketed many kinds of unsaturated polyester
components used for manufacturing glass fiber-reinforced plastic
(hereafter "GFRP" for short). Organic peroxides for thermal curing
by being mixed into the foregoing are also commercially available.
When the two are mixed according to an appropriate recipe, gelling
does not occur at once. Instead, gelling and solidification proceed
as the temperature is raised. Such a mixture can therefore be used
substantially as a one-liquid thermosetting adhesive.
[0092] Despite being two-liquid thermosetting adhesives, therefore,
the latter can be preferably used so long as they have a high
gelling temperature, that the gelling rate after mixing with the
curing agent is very slow around normal temperature, and that the
resulting mixture has a viscosity range no greater than several
hundred Pas. Organic peroxides having a very high decomposition
temperature can be used as curing agents of unsaturated polyesters.
Unsaturated polyesters include alkyd and vinyl ester types.
Stronger adhesive strength itself is achieved when using an
unsaturated polyester of vinyl ester type, in particular an
unsaturated polyester of vinyl ester type manufactured out of an
epoxy resin and methacrylic acid.
[0093] 9. Manufacture of a Composite/Adhesive Bonding Using a
Thermosetting Adhesive
[0094] Epoxy, phenolic and unsaturated polyester adhesives can be
preferably used, as described above. Numerous epoxy and phenolic
adhesives having excellent adhesive performance are marketed. The
adhesive must be in liquid form when applied. High-viscosity
adhesives that are solid at normal temperature can have the
viscosity thereof lowered to arguably that of a liquid, of ten or
more Pas, through heating at 50 to 80.degree. C. It is preferable
to exploit this phenomenon, inasmuch as epoxy adhesives are a
typical instance of such high-viscosity adhesives. The explanation
below focuses therefore on an instance where epoxy adhesives are
used.
[0095] A large vessel, such as a desiccator or the like, capable of
being depressurized, is prepared first. The desiccator is warmed by
being placed in a warm-air dryer for about one hour. Meanwhile, a
galvanized steel sheet surface-treated as described above is
prepared, and the adhesive is coated onto required sites of the
sheet. The desiccator is taken out of the warm-air dryer, and the
steel sheet, coated with the adhesive, is placed in the desiccator.
The desiccator is closed and is evacuated, by way of a vacuum pump,
down to several tens of mmHg to several mmHg. The reduced-pressure
state is maintained for a while, and then the pressure is reverted
back to normal. This operation of depressurization/return to normal
pressure is repeated. As a result of the above operations, the
adhesive, which melts into a liquid on account of the residual heat
of the desiccator, is sucked into the ultra-fine irregularities on
the surface of the steel material.
[0096] The steel sheet is taken out of the desiccator. The steel
sheet and the adherend are closely adhered and fixed to each other,
after which the whole is placed in a hot-air dryer. A temperature
of 100 to 135.degree. C. is held for several tens of minutes to
several hours, during which gelling proceeds. Thereafter, the
temperature is raised from 150 to 200.degree. C. and is held there
for about several tens of minutes to about several hours, during
which curing takes place. The temperature setting varies widely
depending on the curing agent system. Specifically, the temperature
varies depending on the epoxy resin and the curing agent type. The
point is that good bonding is elicited when gelling proceeds
smoothly. If the temperature is raised too high too fast; gelling
and curing occur in a runaway fashion, which ultimately results in
a lower adhesive strength.
[0097] Galvanized steel sheets can be joined to each other by using
an identical galvanized steel sheet as the adherend. Also, the
galvanized steel sheet can be joined to another metal alloy, for
instance a metal alloy other than a similar steel sheet
surface-treated in accordance with the "NAT" theory, such as
surface-treated stainless steel. Carbon fiber-reinforced plastic
(hereafter "CFRP" for short) is an ultra-lightweight, high-strength
material that has a matrix of epoxy resin. Uncured CFRP (i.e. CFRP
prepreg) and a galvanized steel sheet coated with an epoxy adhesive
are affixed to each other by way of clips. In this affixed state,
the whole is heated in a hot-air dryer to cure the entire epoxy
component, whereupon the epoxy adhesive and the CFRP portion
solidify competitively. A strong integrated product of the
galvanized steel sheet and the CFRP can be obtained as a
result.
[0098] When using a phenolic adhesive as the adhesive, strong
joining is achieved between abrasive materials or friction
materials having a phenolic resin matrix. Also, GFRP having an
unsaturated polyester resin matrix can be easily joined when using
an unsaturated polyester adhesive as the adhesive. In the case of
both CFRP and GFRP, an adhesive-coated galvanized steel sheet and
prepreg are brought into contact with each other, are fixed, and
are subjected to thermal curing in that state, whereupon the
adhesive and the prepreg become fixed to each other, thereby
yielding a composite in which the galvanized steel sheet and the
FRP are strongly joined and integrated together.
[0099] 10. Applications
[0100] The present invention, which provides a technology for
strongly bonding a galvanized steel sheet and an adherend (metal
alloy or resin molded article or FRP), can be used in various
fields. The above technology, specifically, can be used in, for
instance, construction materials, outdoors equipment, construction
machinery parts, and in the manufacture parts in ordinary
equipment. The technology of the invention enables novel design
approaches in the manufacture of such elements. The present
invention lays the basic technology for manufacturing parts
relating to galvanized steel sheets, and can thus be expected to
find application in fields other than the above. In all cases, the
technology should contribute to improving the performance and
productivity of various parts.
[0101] In the composite of the present invention, as explained in
detail above, a resin molded article and a galvanized steel sheet
are strongly integrated together in such a manner that they do not
readily come apart. Thus, a composite can be manufactured in which
a galvanized steel sheet and a resin molded article are strongly
integrated together, by subjecting a galvanized steel sheet to a
predetermined surface treatment, and through injection bonding of a
thermoplastic resin composition comprising 70 to 97 wt % of PBT and
30 to 3 wt % of PET and/or a polyolefin resin; a thermoplastic
resin composition comprising 70 to 97 wt % of PPS and 3 to 30 wt %
of a polyolefin resin; or a thermoplastic resin composition
comprising both an aromatic polyamide and an aliphatic
polyamide.
[0102] Alternatively, a temporary resin molded article is
manufactured, by injection molding, using a thermoplastic resin
composition that comprises, for instance, PBT, PPS, a polyamide or
a liquid crystal polymer, while a galvanized steel sheet is
subjected to a surface treatment according to the present
invention. The surface-treated galvanized steel sheet is then
heated, and the above resin molded article is pressed against the
galvanized steel sheet, to elicit press-fusion bonding
therebetween. As a result there can be manufactured a composite in
which the galvanized steel sheet and the resin molded article are
integrated together. Further, the present invention allows strongly
joining a galvanized steel sheet with an adherend (metal alloy and
CFRP) by subjecting a galvanized steel sheet to a predetermined
surface treatment, and by using for instance a
commercially-available epoxy adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0103] FIG. 1 is a cross-sectional diagram of an injection mold for
manufacturing a composite through injection of a thermoplastic
resin composition onto a galvanized steel sheet;
[0104] FIG. 2 is a diagram illustrating the shape of a composite of
a resin molded article and a galvanized steel sheet, obtained by
injection bonding;
[0105] FIG. 3 is a diagram illustrating the shape (boss shape) of a
molded article of a thermoplastic resin used in press-fusion
bonding;
[0106] FIG. 4 is a side-view diagram of a molded article of a
thermoplastic resin used in press-fusion bonding;
[0107] FIG. 5 is a cross-sectional diagram of a jig used for
press-fusion bonding a resin molded article onto a galvanized steel
sheet;
[0108] FIG. 6 is a plan-view diagram of a galvanized steel sheet
used in press-fusion bonding;
[0109] FIG. 7 is a diagram illustrating the shape of a composite of
a resin molded article and a galvanized steel sheet, obtained by
press-fusion bonding;
[0110] FIG. 8 is a schematic diagram of an apparatus for measuring
the breaking strength of a composite obtained by press-fusion
bonding;
[0111] FIG. 9 is a cross-sectional diagram of a baking jig for
bonding, and thermally curing, CFRP to a galvanized steel sheet by
way of a one-liquid thermosetting adhesive;
[0112] FIG. 10 is a diagram illustrating the shape of composite in
which a galvanized steel sheet and CFRP are joined by way of a
one-liquid thermosetting adhesive;
[0113] FIG. 11 is a diagram illustrating the shape of a bonded body
in which galvanized steel sheets are joined to each other by way of
a one-liquid thermosetting adhesive;
[0114] FIG. 12 is a cross-sectional diagram illustrating the
surface structure of a metal alloy in new NMT and NAT;
[0115] FIG. 13 is an electron micrograph (10,000 magnifications) of
a commercially-available hot-dip galvanized steel sheet "Z-18"
after being subjected to a light degreasing treatment;
[0116] FIG. 14 is an electron micrograph (100,000 magnifications)
of a commercially-available hot-dip galvanized steel sheet "Z-18"
after being subjected to a light degreasing treatment;
[0117] FIG. 15 is an electron micrograph (10,000 magnifications) of
a commercially-available hot-dip galvanized steel sheet "Z-18"
after being immersed in a zinc phosphate conversion treatment
solution;
[0118] FIG. 16 is an electron micrograph (100,000 magnifications)
of a commercially-available hot-dip galvanized steel sheet "Z-18"
after being immersed in a zinc phosphate conversion treatment
solution;
[0119] FIG. 17 is an electron micrograph (10,000 magnifications) of
a commercially-available hot-dip galvanized steel sheet "Z-18"
after being immersed in a zinc calcium phosphate conversion
treatment solution;
[0120] FIG. 18 is an electron micrograph (100,000 magnifications)
of a commercially-available hot-dip galvanized steel sheet "Z-18"
after being immersed in a zinc calcium phosphate conversion
treatment solution;
[0121] FIG. 19 is an electron micrograph (10,000 magnifications) of
a commercially-available hot-dip galvanized steel sheet "Z-18"
after being immersed in a conversion treatment solution for steel
materials comprising trivalent chromium and hexavalent
chromium;
[0122] FIG. 20 is an electron micrograph (100,000 magnifications)
of a commercially-available hot-dip galvanized steel sheet "Z-18"
after being immersed in a conversion treatment solution for steel
materials comprising trivalent chromium and hexavalent
chromium;
[0123] FIG. 21 is an electron micrograph (10,000 magnifications) of
a commercially-available hot-dip zinc-aluminum alloy coated steel
sheet "GLAZ-150" after being etched in dilute sulfuric acid and
subjected to a zinc phosphate conversion treatment;
[0124] FIG. 22 is an electron micrograph (100,000 magnifications)
of a commercially-available hot-dip zinc-aluminum alloy coated
steel sheet "GLAZ-150" after being etched in dilute sulfuric acid
and subjected to a zinc phosphate conversion treatment;
[0125] FIG. 23 is an electron micrograph (10,000 magnifications) of
a commercially-available hot-dip zinc-aluminum alloy coated steel
sheet "GLAZ-150" after being subjected to a degreasing treatment;
and
[0126] FIG. 24 is an electron micrograph (100,000 magnifications)
of a commercially-available hot-dip zinc-aluminum alloy coated
steel sheet "GLAZ-150" after being subjected to a degreasing
treatment.
BEST MODE FOR CARRYING OUT THE INVENTION
[0127] Embodiments of the present invention are explained
below.
[0128] Injection Bonding Method
[0129] FIG. 1 and FIG. 2 are diagrams relating to injection bonding
of a thermoplastic resin. FIG. 1 is a cross-sectional diagram
illustrating schematically an injection mold used in the
below-described experimental examples. FIG. 1 illustrates injection
molding with the mold in a closed state. FIG. 2 is an external-view
diagram of a composite 7 comprising a galvanized steel sheet and a
resin molded article molded in an injection mold. The injection
mold comprises a movable mold plate 2, a stationary mold plate 3,
and a resin injector comprising a pinpoint gate 5, a runner and so
forth, on the side of the stationary mold plate 3.
[0130] The composite 7 is molded in accordance with the following
procedure. Firstly, the movable mold plate 2 is opened and a
galvanized steel sheet piece 1 is inserted into the cavity formed
between the movable mold plate 2 and the stationary mold plate 3.
After insertion, the movable mold plate 2 is closed, which results
in the state before injection in FIG. 1. A molten resin composition
is then injected, via the pinpoint gate 5, into the cavity in which
the galvanized steel sheet piece 1 has been inserted.
[0131] Upon injection, the resin composition becomes joined to an
end of the galvanized steel sheet piece 1 and is molded by filling
the cavity. As a result, a composite 7 is obtained in which the
galvanized steel sheet piece 1 and the resin molded article 4 are
integrated together. The composite 7 has a joining face 6 between
the galvanized steel sheet piece 1 and the resin molded article 4.
The surface area of the joining face 6 is 5 mm.times.10 mm.
Accordingly, the surface area of the joining face 6 is 0.5
cm.sup.2.
[0132] Press-Fusion Bonding Method
[0133] FIG. 3, FIG. 4, FIG. 5, FIG. 6 and FIG. 7 are diagrams
relating to press-fusion bonding a galvanized steel sheet piece and
a resin molded article. FIG. 3 is a diagram illustrating the shape
of a molded article of a thermoplastic resin used in the
below-described experimental examples. FIG. 4 illustrates an
example of shape design in which the above-described resin molded
article is shaped as a boss having a protrusion jutting about 0.1
mm outwards from the center of the boss bottom. When forming a
filled-type boss shape by injection bonding, the center of the boss
bottom sinks inevitably on account of molding shrinkage by the
resin composition. Parts with a sunk bottom are not preferred for
press-fusion bonding. Such parts should therefore be designed
beforehand in such a manner that the center of the bottom thereof
bulges out. As a result, the central portion of the boss bottom
bulges preferably out by about 0.1 mm, or at worst is flat,
although molding may rely on a pin gate, as illustrated in FIG.
4.
[0134] FIG. 5 illustrates an example of a jig for manufacturing a
composite wherein two bosses are fusion-bonded to a galvanized
steel sheet piece by press-fusion bonding. A galvanized steel sheet
piece 13, heated using a hot plate or the like, is placed in a
recess provided on the top face of a heat-insulating material 12
that is built into a jig lower die 11. A jig upper die 19, together
with a resin molded article 22 (article extending from the boss up
to the cutoff at the runner in FIG. 3) set beforehand in the jig
upper die 19, are pushed against the jig lower die 11. A two-way
stopcock 28 is opened at substantially at the same time, whereupon
the entire system, having a line connected to a vacuum pump 26
driven beforehand, is depressurized to several mmHg. After several
seconds, a four-way stopcock 27 is turned 90 degrees to revert the
entire system to normal pressure. As a result of the above series
or operations, the bottom of the molten resin molded article 22
comes into contact with the galvanized steel sheet piece 13,
whereupon the resin melt penetrates readily into the micron-scale
recesses, and into the ultra-fine irregularities, on the surface of
the galvanized steel sheet piece 13.
[0135] The melt solidifies upon subsequent cooling, and then the
jig upper die 19 is lifted off the jig lower die 11, and the
adhered composite 30 is demolded from the press-fusion bonding jig.
The obtained composite 30 is preferably annealed for about 1 hour.
The annealing temperature varies depending on the melting point of
the resin composition, but is preferably of about 150.degree. C.
for PBT and polyamides, and about 170.degree. C. for PPS or the
like. FIG. 6 illustrates the shape of the galvanized steel sheet
piece 13 that is to be press-fused, and which is set in the jig
lower die 11 illustrated in FIG. 5. As illustrated in FIG. 6, a
plurality of screw holes 32 for carrying out tensile tests are
drilled in the galvanized steel sheet piece 13. The galvanized
steel sheet piece having a plurality of the screw holes 32 provided
therein is press-fused to the resin molded article 31, to yield
ultimately the composite 30, as illustrated in FIG. 7.
[0136] Method for Joining a Galvanized Steel Sheet Piece and a
Metal Alloy Piece
[0137] FIG. 11 illustrates the shape of a bonded body 60 obtained
by bonding two galvanized steel sheet pieces (61, 62) to each other
by way of an adhesive. FIG. 11 will be referred to in the
experimental examples set out below. The galvanized steel sheet
nieces 61, 62 are both 45 mm.times.18 mm pieces, and the adhesion
area therebetween (surface area of the hatched portion 63 in FIG.
11) is about 0.5 to 0.6 cm.sup.2. Shear rupture strength is
measured by pulling on the bonded body 60 until breakage. One of
the pieces that make up the bonded body 60 may be not a galvanized
steel sheet piece, but a piece of a dissimilar metal alloy.
Particularly strong bonding strength is achieved when the metal
alloy is an aluminum alloy, a magnesium alloy, a copper alloy, a
titanium alloy, stainless steel or an ordinary steel material,
having been surface-treated in accordance with "NAT".
[0138] Method for Bonding a Galvanized Steel Sheet Piece and a CFRP
Piece
[0139] FIG. 9 illustrates a baking jig 41 of a composite of a CFRP
piece and a galvanized steel sheet piece. FIG. 10 illustrates the
shape of a composite 50 of a CFRP piece 52 and a galvanized steel
sheet piece 51 obtained using the baking jig 41. The baking jig 41
has a mold body 42 and a rectangular mold recess 43 opened on the
top face of the mold body 42. A mold through-hole 44 is formed in
the bottom of the mold body 42.
[0140] A bottom plate projection 46 is inserted through a mold
through-hole 44 in the underside of the mold bottom plate 45. The
bottom plate projection 46 projects out of a mold bottom face 47 of
the mold body 42. The bottom face of the mold body 42 rests on a
mold seat 48. With the mold bottom plate 45 inserted in the mold
recess 43 of the mold body 42, a composite 50 is manufactured
through baking of the galvanized steel sheet piece 51 and the CFRP
piece 52, joined by way of an adhesive, as illustrated in FIG. 10.
The composite 50 is manufactured in accordance with the procedure
outlined below. Firstly, a demolding film 57 is laid over the
entire surface of the mold bottom plate 45. Next, a plate-like
spacer 56 and the galvanized steel sheet piece 51 having an
adhesive coated thereon are placed on the demolding film 57. A
desired CFRP prepreg is laid on the end of the spacer 56 and the
galvanized steel sheet piece 51. The space between the stacked CFRP
prepreg (which constitutes the CFRP piece 52 after curing) and the
inner wall face of the mold body 42 is occupied by a spacer 53.
[0141] A demolding film 54 is overlaid so as to cover the spacer 53
and the stacked CFRP prepreg. A weight in the form of a PTFE block
55 of PTFE (polytetrafluoroethylene resin) is placed on the
demolding film 54. A weight 58 of several hundred g is further laid
thereon. The entire baking jig is then placed, in this state, in a
hot-air dryer, where the CFRP prepreg is cured and left to cool.
Thereafter, the weights 58, the seat 48 and so forth are removed,
and the lower end of the bottom plate projection 46 is pushed
against the floor. In doing so, the bottom plate projection 46 is
pushed and only the mold body 42 is brought down and the composite
50, resulting from joining and bonding of the CFRP piece 52 (cured
CFRP prepreg) and the galvanized steel sheet piece 51, is removed
from the mold body 42, together with the demolding films 54, 57.
The spacers 53, 56 and the demolding films 54, 57 are non-adhesive
materials, and can thus be easily stripped off the CFRP piece
52.
[0142] The instruments used in the present invention were as
follows.
[0143] Measurement of PPS Melt Viscosity
[0144] The melt viscosity is measured using a Koka type flow tester
"CPT-500 (by Shimadzu)" equipped with a die of 1 mm in diameter and
2 mm long, at a measurement temperature of 315.degree. C., and a
load of 98 N (10 kgF).
[0145] Observation of the Galvanized Steel Sheet Surface
[0146] (a) XPS Observation Using an X-Ray Photoelectron
Spectrometer
[0147] The galvanized steel sheet surface was analyzed (XPS
observation) using a photoelectron spectrometer that, for instance,
determines elements qualitatively by analyzing the energy of
photoelectrons that are emitted by a sample when the latter is
irradiated with X-rays. The photoelectron spectrometer used herein
was "AXIS-Nova" (by Kratos Analytical/Shimadzu), which affords
observations to a depth of several nm over a surface several .mu.m
across.
[0148] (b) Electron Microscopy
[0149] The surface of galvanized steel sheets was observed using
electron microscopes. The electron microscopes employed were a
scanning (SEM) electron microscope "S-4800" (by Hitachi) and
"JSM-6700F" (by JEOL), at 1 to 2 kV.
[0150] (c) Scanning Probe Microscopy
[0151] The surface of galvanized steel sheets was observed using a
scanning electron microscope. The microscope is a scanning probe
microscope "SPM-9600 (by Shimadzu)" wherein a probe in the form of
a sharp-tip needle traces the surface of a substance, to observe
thereby the magnified surface morphology.
[0152] Measurement of the Adhesive Strength of Composites
[0153] Shear rupture strength was measured in the form of the
rupture strength upon breakage of the composite when the latter is
acted upon by a tensile shear force in a tensile tester. A tensile
tester "Model 1323 (Aikoh Engineering, Japan)" was used to measure
shear rupture strength, at a pulling rate of 10 mm/minute.
Preparative Example 1
Preparation of PPS Composition (1)
[0154] A 50 L autoclave equipped with a stirrer was charged with
6214 g of a sodium sulfide (nonahydrate) Na.sub.2S.9H.sub.2O and
17000 g of N-methyl-2-pyrrolidone. The temperature was gradually
raised to 205.degree. C. under stirring and under a nitrogen gas
stream, and 1355 g of water were distilled off. The system was
cooled to 140.degree. C., after which 7160 g of p-dichlorobenzene
and 5000 g of N-methyl-2-pyrrolidone were added. The system was
sealed under a nitrogen gas stream. The temperature of the system
was raised to 225.degree. C. over 2 hours, whereupon polymerization
proceeded for 2 hours at 225.degree. C. Thereafter, the temperature
of the system was raised to 250.degree. C. over 30 minutes,
whereupon polymerization proceeded for another 3 hours at
250.degree. C. Once polymerization was over, the system was cooled
to room temperature and the resulting polymer was separated in a
centrifugal separator. The solid fraction of the polymer was
repeatedly washed with warm water and was dried overnight at
100.degree. C. The resulting PPS (hereinafter referred to as PPS
(1)) exhibited a melt viscosity of 280 poise.
[0155] This PPS (1) was further cured for 3 hours at 250.degree. C.
in a nitrogen atmosphere to yield a PPS (2). The melt viscosity of
the obtained PPS (2) was 400 poise.
[0156] Next, 6.0 kg of the resulting PPS (2), 1.5 kg of an
ethylene-acrylic ester-maleic anhydride terpolymer "Bondine TX8030
(by Arkema)" and 0.5 kg of epoxy resin "Epikote 1004 (by Japan
Epoxy Resin)" were mixed uniformly beforehand in a tumbler.
Thereafter, melt kneading was carried out in a biaxial extruder
"TEM-35B (by Toshiba Machine)" at a cylinder temperature of
300.degree. C., under supply of glass fibers having an average
fiber diameter of 9 .mu.m and a fiber length of 3 mm "RES03-TP91
(made Nippon Sheet Glass)" through a side feeder, to an addition
amount of 20 wt %. A pelletized PPS composition (1) was obtained as
a result. The obtained PPS composition (1) was dried for 5 hours at
175.degree. C.
Preparative Example 2
Preparation of PPS Composition (2)
[0157] The PPS (1) obtained in Preparative example 1 was cured for
3 hours at 250.degree. C. in an oxygen atmosphere to yield a PPS
(3). The melt viscosity of the obtained PPS (3) was 1800 poise.
[0158] Next, 5.98 kg of the resulting PPS (3) and 0.02 kg of
polyethylene "Nipolon Hard 8300A (by Tosoh)" were mixed uniformly
beforehand in a tumbler. Thereafter, melt kneading was carried out
in a biaxial extruder "TEM-35B" at a cylinder temperature of
300.degree. C., under supply of glass fibers having an average
fiber diameter of 9 .mu.m and a fiber length of 3 mm "RES03-TP91"
through a side feeder, to an addition amount of 40 wt %. A
pelletized PPS composition (2) was obtained as a result. The
obtained PPS composition (2) was dried for 5 hours at 175.degree.
C.
Preparative Example 3
Preparation of PPS Composition (3)
[0159] Herein, 7.2 kg of the PPS (2) obtained in Preparative
example 1 and 0.8 kg of a glycidyl methacrylate-ethylene copolymer
"Bondfast E (by Sumitomo Chemical)" were mixed uniformly beforehand
in a tumbler. Thereafter, melt kneading was carried out in a
biaxial extruder "TEM-35B" at a cylinder temperature of 300.degree.
C., under supply of glass fibers having an average fiber diameter
of 9 .mu.m and a fiber length of 3 mm "RES03-TP91" through a side
feeder, to an addition amount of 20 wt %. A pelletized PPS
composition (3) was obtained as a result. The obtained PPS
composition (3) was dried for 5 hours at 175.degree. C.
Preparative Example 4
Preparation of PPS Composition (4)
[0160] Herein, 4.0 kg of the PPS (2) obtained in Preparative
example 1 and 4.0 kg of an ethylene-acrylic ester-maleic anhydride
terpolymer "Bondine TX8030" were mixed uniformly beforehand in a
tumbler. Thereafter, melt kneading was carried out in a biaxial
extruder "TEM-35B" at a cylinder temperature of 300.degree. C.,
under supply of glass fibers having an average fiber diameter of 9
.mu.m and a fiber length of 3 mm "RES03-TP91" through a side
feeder, to an addition amount of 20 wt %. A pelletized PPS
composition (4) was obtained as a result. The obtained PPS
composition (4) was dried for 5 hours at 175.degree. C.
Preparative Example 5
Preparation of PBT Composition (1)
[0161] Herein, 4.5 kg of a PBT resin "Toraycon 1100S (by Toray)"
and 0.5 kg of a PET resin "TR-4550BH (by Teijin Kasei)" were mixed
uniformly beforehand in a tumbler. Thereafter, melt kneading was
carried out in a biaxial extruder "TEM-35B" at a cylinder
temperature of 270.degree. C., under supply of glass fibers having
an average fiber diameter of 9 .mu.m and a fiber length of 3 mm
"RES03-TP91" through a side feeder, to an addition amount of 30 wt
%. A pelletized PBT resin composition was obtained as a result. The
obtained PBT composition (1) was dried for 3 hours at 140.degree.
C.
Preparative Example 6
Preparation of PBT Composition (2)
[0162] Herein, 6.0 kg of PBT resin "Toraycon 1401X31 (by Toray),
0.7 kg of an ethylene-acrylic ester-maleic anhydride terpolymer
"Bondine TX8030" and 0.15 kg of epoxy resin "Epikote 1004" were
mixed uniformly beforehand in a tumbler. Thereafter, melt kneading
was carried out in a biaxial extruder "TEM-35B" at a cylinder
temperature of 270.degree. C., under supply of glass fibers having
an average fiber diameter of 9 .mu.m and a fiber length of 3 mm
"RES03-TP91" through a side feeder, to an addition amount of 30 wt
%. A pelletized PBT composition (2) was obtained as a result. The
obtained PBT composition (2) was dried for 5 hours at 150.degree.
C.
Preparative Example 7
Preparation of PBT Composition (3)
[0163] Herein, 6.0 kg of a PBT resin "Toraycon 1401X31", 0.5 kg of
a PET resin "TR-4550BH", 0.5 kg of an ethylene-acrylic ester-maleic
anhydride terpolymer "Bondine TX8030" and 0.1 kg of epoxy resin
"Epikote 1004" were mixed uniformly beforehand in a tumbler.
Thereafter, melt kneading was carried out in a biaxial extruder
"TEM-35B" at a cylinder temperature of 270.degree. C., under supply
of glass fibers having an average fiber diameter of 9 .mu.m and a
fiber length of 3 mm "RES03-TP91" through a side feeder, to an
addition amount of 30 wt %. A pelletized PBT composition (3) was
obtained as a result. The obtained PBT composition (3) was dried
for 5 hours at 150.degree. C.
Experimental Example 1
Preparation of a Galvanized Steel Sheet Piece
[0164] A 0.4 mm-thick oiled and chromate-treated hot-dip galvanized
steel sheet "Z18 (by Nippon Steel & Sumikin Metal Products)"
was procured, and was cut into multiple 18 mm.times.45 mm
rectangular galvanized steel sheet pieces. An aqueous solution at a
liquid temperature of 75.degree. C. containing 7.5% of a
commercially available degreasing agent for aluminum alloys "NE-6
(by Meltex)" was prepared in a bath, to yield a degreasing aqueous
solution. Then, 5 galvanized steel sheet pieces were immersed for 7
minutes in this degreasing bath, were then thoroughly rinsed with
deionized water, and were dried at 90.degree. C. for 15 minutes in
a hot-air dryer.
[0165] Two days later, one of the pieces was cut and observed under
a scanning probe microscope. When scanned 6 times over a length of
20 .mu.m, the pieces exhibited a peak-valley average spacing RSm of
0.8 to 1.8 .mu.m and a maximum height roughness Rz of 0.3 to 0.9
.mu.m. The measurement results for 20 scannings yielded an RSm of
0.8 to 2.3 .mu.m and a maximum height roughness Rz of 0.3 to 1.0
.mu.m. Electron microscopy revealed that the surface of the
galvanized steel sheet pieces was covered with innumerable
clean-cut convex protrusions having a diameter of about 100 nm. It
was found that the chromate treatment layer on the hot-dip
galvanized steel sheet that was used was exposed through the
oil-removing action of the degreasing step, or that organic matter
or polymer components comprised in the chromate treatment had
sloughed off. That is, the surface of the galvanized steel sheet
pieces satisfies the first to third conditions of "new NMT" and
"NAT" as a result of the degreasing treatment alone. This surface
treatment method, moreover, requires no surface hardening
treatment, no chemical etching treatment and no fine etching
treatment, and can hence contribute to shortening the duration, and
lowering the cost, of the composite manufacturing process.
Experimental Example 2
Preparation of a Galvanized Steel Sheet Piece: Comparative
Example
[0166] A plurality of galvanized steel sheet pieces was prepared by
cutting a hot-dip galvanized steel sheet "Z18", the same as used in
Experimental example 1, into 18 mm.times.45 mm rectangular pieces,
An aqueous solution at a liquid temperature of 50.degree. C., lower
than that of Experimental example 1, and containing 7.5 of a
degreasing agent for aluminum alloys "NE-6" was prepared in a bath,
to yield a degreasing aqueous solution. The galvanized steel sheet
pieces were immersed for 2 minutes in the degreasing bath, were
thoroughly rinsed with water, and were dried in a hot-air dryer at
90.degree. C. for 15 minutes.
[0167] FIG. 13 and FIG. 14 illustrate the observation results of
the obtained galvanized steel sheet pieces in an electron
microscope at 10,000 magnifications and 100,000 magnifications.
FIG. 13 shows extremely shallow irregularities, in the form of
protrusion groups having a diameter of about 100 nm that can be
seen through fissures, within a substantially flat greater area. In
FIG. 14, the flat area is viewed at 100,000 magnifications. What is
seen within the shallow irregularities were believed to be
protrusion groups, having a diameter of about 100 nm, standing
immediately below the flat surface (electron beams from the
electron microscope traverse the top layer and are reflected by
hard matter disposed immediately below). The surface of
Experimental example 1 resulted from stripping the top layer and
enlarging the fissure portions observable in FIG. 13. That is, the
micrographs showed that the above surface does not have a
micron-scale roughness according to the first condition.
Experimental Example 3
Preparation of a Galvanized Steel Sheet Piece
[0168] A plurality of galvanized steel sheet pieces were prepared
by cutting a hot-dip galvanized steel sheet "Z18", the same as used
in Experimental example 1, into 18 mm.times.45 mm rectangular
pieces. An aqueous solution at a liquid temperature of 75.degree.
C. containing 7.5% of a degreasing agent for aluminum alloys "NE-6"
was prepared in a bath, to yield a degreasing aqueous solution. In
a separate dipping bath there was prepared a zinc phosphate
conversion treatment solution at 55.degree. C. containing 1.2% of
orthophosphoric acid, 0.21% of zinc oxide, 0.16% of sodium
fluorosilicate and 0.23% of basic nickel carbonate.
[0169] The galvanized steel sheet pieces were first immersed for 5
minutes in the degreasing bath and were then rinsed with water. The
pieces were immersed in the conversion treatment bath for 1 minute,
and were rinsed with water. The pieces were dried at 90.degree. C.
for 15 minutes. In this experiment fine hydrogen bubbles were
observed during immersion in the conversion treatment bath. This
indicated that zinc was dissolved and ionized through the acidity
of phosphoric acid. The conversion treatment doubles thus herein as
both a "chemical etching" and a "surface hardening" (the purposes
intended originally by the inventors for the conversion
treatment).
[0170] Two days later, one of the pieces was cut and observed under
an electron microscope and a scanning probe microscope. FIG. 15 and
FIG. 16 illustrate electron microscopy results at 10,000
magnifications and 100,000 magnifications. FIG. 16 shows that the
entire surface was covered with ultra-fine irregularities in the
form of protrusions of irregular polyhedral shapes, having a
diameter of 20 to 150 nm (average diameter about 50 nm) stacked on
one another. The results of a measurement involving 10 scannings
over a length of 20 using a scanning probe microscope revealed a
peak-valley average spacing RSm of 1.5 to 2.3 .mu.m and a maximum
height roughness Rz of 0.5 to 1.5 .mu.m. The results of electron
microscopy showed that there is obtained the ultrafine irregular
surface that is demanded by "new NMT" and by "NAT", and that
"chemical etching", "fine etching" and "surface hardening" are
achieved simultaneously. This surface treatment method satisfies
the first through third conditions, and hence requires no separate
chemical etching treatment or fine etching treatment. Therefore,
the surface treatment method contributes to shortening the
duration, and lowering the cost, of the composite manufacturing
process.
Experimental Example 4
Preparation of Galvanized Steel Sheet Pieces
[0171] A plurality of galvanized steel sheet pieces were prepared
by cutting a hot-dip galvanized steel sheet "Z18", the same as used
in Experimental example 1, into 18 mm.times.45 mm rectangular
pieces. An aqueous solution at a liquid temperature of 75.degree.
C. containing 7.5% of a commercially available degreasing agent for
aluminum alloys "NE-6" was prepared in a bath, to yield a
degreasing aqueous solution. In a separate bath there was prepared
a zinc calcium phosphate-type conversion treatment solution at
65.degree. C., and containing 1.2% of orthophosphoric acid, 0.2% of
zinc nitrate, 0.3% of calcium nitrate and 0.2% of basic nickel
carbonate.
[0172] The galvanized steel sheet pieces were first immersed for 5
minutes in the degreasing bath and were then rinsed with water. The
pieces were immersed in the conversion treatment bath for 1 minute,
and were rinsed with water. The pieces were dried at 90.degree. C.
for 15 minutes. Fine hydrogen bubbles were observed to form in the
conversion treatment bath. This indicated that the galvanization
layer was dissolved and ionized through the acidity of phosphoric
acid. The conversion treatment doubles thus herein as both
"chemical etching" and "surface hardening" (the purpose intended by
the inventors for the conversion treatment). The results of a
measurement involving 6 scannings over a length of 20 .mu.m using a
scanning probe microscope revealed a peak-valley average spacing
RSm of 2.5 to 4 .mu.m and a maximum height roughness Rz of 0.3 to
0.8 .mu.m.
Experimental Example 5
Preparation of Galvanized Steel Sheet Pieces
[0173] An experiment identical to Experimental example 4 was
performed. Herein, however, there was used a commercially-available
zinc calcium phosphate conversion treatment solution instead of the
zinc calcium phosphate conversion treatment solution prepared from
scratch that was used in Experimental example 4. In the present
Experimental example 5 there was used "Palbond 880 (by Nihon
Parkerizing)". The ordinary use conditions of "Palbond 880" (use
conditions during the conversion treatment of the steel material)
involve a liquid temperature of 80 to 90.degree. C., and immersion
of the steel material for about 2 minutes. In the present
invention, by contrast, the conditions were significant milder.
Specifically, immersion lasted for 1 minute at a liquid temperature
of 65.degree. C.
[0174] A galvanized steel sheet piece subjected to the above
surface treatment was observed under an electron microscope and a
scanning probe microscope. FIG. 17 and FIG. 18 illustrate electron
microscopy results at 10,000 magnifications and 100,000
magnifications. The micrographs show a surface entirely covered
with piles of irregular polyhedral plates having a long-short
diameters of 80 to 200 nm. Measurements under the scanning probe
microscope revealed a rough surface having an average texture
period RSm of 2.8 to 3.6 .mu.m and a maximum height roughness Rz of
0.4 to 1.3 .mu.m. This surface treatment method satisfies the first
to third conditions, and hence requires no separate chemical
etching treatment or fine etching treatment. Therefore, the surface
treatment method contributes to shortening the duration, and
lowering the cost, of the composite manufacturing process.
Experimental Example 6
Preparation of Galvanized Steel Sheet Pieces
[0175] An experiment identical to Experimental example 3 was
performed. Herein, however, there was used a different chromate
treatment aqueous solution at 40.degree. C., namely containing 1.2%
of chromium nitrate hydrate, 0.3% of chromium trioxide, 1.5% of
orthophosphoric acid, and 0.033% of basic nickel carbonate, instead
of the zinc phosphate conversion treatment used in Example 3.
[0176] A treatment solution of such a system, developed to be
comparatively closest to treatment solutions used in ordinary steel
materials (iron alloys), contains characteristically trivalent
chromium and hexavalent chromium, and is an excellent conversion
treatment solution for chromate treatment of steel materials. The
galvanized steel sheet piece was degreased, rinsed with water and
subjected to a conversion treatment in the same way as in
Experimental examples 3, 4 and 5. The solution had a strong
coloration, and hence the presence or absence of bubbles could not
be assessed. After the conversion treatment, the pieces were
thoroughly rinsed with deionized water, and were dried for 15
minutes at 90.degree. C.
[0177] The galvanized steel sheet piece thus treated was observed
under an electron microscope and a scanning probe microscope. FIG.
19 and FIG. 20 illustrate electron microscopy results at 10,000
magnifications and 100,000 magnifications. The figures show a
surface entirely covered with ultra-fine irregularities of
indefinite period of 10 to 200 nm. Measurements using a scanning
probe microscope revealed a rough surface having a peak-valley
average spacing RSm of 1.3 to 2.5 .mu.m and a maximum height
roughness Rz of 0.3 to 1.5 .mu.m.
Experimental Example 7
Preparation of Galvalume Steel Sheet Pieces
[0178] A 0.6 mm-thick hot-dip zinc-aluminum alloy coated steel
sheet (commonly referred to as galvalume steel sheet) "GL-AZ150 (by
Nisshin Steel)" was cut into 18 mm.times.45 mm rectangular pieces,
to prepare a plurality of zinc-aluminum alloy coated steel sheet
pieces. An aqueous solution at a liquid temperature of 60.degree.
C. containing 7.5% of a commercially available degreasing agent for
aluminum "NE-6" was prepared in a bath, to yield a degreasing
aqueous solution. In a separate bath there was prepared a 1.5%
aqueous solution of caustic soda at 40.degree. C., as an aqueous
solution for preliminary basic washing. Also, an aqueous solution
containing 5% sulfuric acid at 50.degree. C. was prepared as an
etching solution. In another separate bath there was prepared 1%
aqueous ammonia at 25.degree. C., for neutralization. In yet
another separate bath there was prepared a zinc phosphate
conversion treatment solution at 55.degree. C. containing 1.5% of
80% orthophosphoric acid, 0.21% of zinc oxide, 0.16% of sodium
fluorosilicate and 0.23% of basic nickel carbonate. The
zinc-aluminum alloy coated steel sheet pieces were first immersed
in the degreasing bath for 5 minutes, and were rinsed with water.
Next, the pieces were immersed for 1 minute in the preliminary
basic washing bath, and were rinsed with water. The pieces were
immersed next in the etching bath for 1 minute, and were rinsed
with water. Next, the pieces were immersed in the neutralization
bath for 1 minute, and were rinsed with water. The pieces were
immersed next in the conversion treatment layer for 1 minute, and
were rinsed with water. Thereafter, the pieces were dried at
90.degree. C. for 15 minutes, to complete the surface
treatment.
[0179] Two days later, one of the pieces was cut and observed under
an electron microscope and a scanning probe microscope. FIG. 21 and
FIG. 22 illustrate electron microscopy results at 10,000
magnifications and 100,000 magnifications. The figures show that
the surface is entirely covered with ultra-fine irregularities in
the form of clustered protrusions, of varying height and having a
diameter of 30 to 300 nm, in which the ends of irregular polyhedral
rods, having a diameter of 30 to 50 nm, come into contact with one
another. Described alternatively, the surface is entirely covered
with ultra-fine irregularities in the form of irregular polyhedral
protrusions, having a diameter of 20 to 300 nm, heaped onto one
another. Measurements under the scanning probe microscope revealed
a rough surface having an average texture period RSm of 2.8 to 3.8
.mu.m and a maximum height roughness Rz of 1.1 to 1.8 .mu.m.
[0180] For verification, steel sheet pieces of a hot-dip
zinc-aluminum alloy coated steel sheet "GL-AZ150" not having
undergone the above-described surface treatment were dipped for 5
minutes in the above-described degreasing bath, were rinsed with
water and were dried, whereupon micrographs thereof were taken at
10,000 magnifications and 100,000 magnifications. The results are
illustrated in FIG. 23 and FIG. 24. The micrographs show a surface
virtually devoid of ultra-fine irregularities. This absence of
irregularities implied that the steel sheet had not been subjected
to a chromate treatment, a zinc phosphate conversion treatment or a
zinc calcium phosphate conversion treatment.
Experimental Example 8
Injection Bonding
[0181] The surface-treated galvanized steel sheet pieces in
Experimental example 6 were taken out, were picked up using gloves,
to prevent adhesion of grease or the like, and were inserted into
an injection mold. The mold was closed and the PPS composition (1)
obtained in Preparative example 1 was injected at an injection
temperature of 310.degree. C. The mold temperature was 140.degree.
C. This injection bonding yielded 20 integrated composites 7
illustrated in FIG. 2. The size of the resin portion was 10
mm.times.45 mm.times.5 mm. The adhesion area was 10 mm.times.5
mm=0.5 cm.sup.2. Annealing was performed on the same day of
molding, in a hot-air dryer at 170.degree. C. for 1 hour. One day
later, the composites were tested in a tensile tester, which
yielded an average shear rupture strength of 21.8 MPa.
Experimental Example 9
Injection Bonding: Comparative Example
[0182] An experiment was conducted in the same way as in
Experimental example 8, but using herein the PPS composition (2)
obtained in Preparative example 2 instead of the PPS composition
(1) obtained in Preparative example 1. Composites were obtained
through injection bonding using the surface-treated galvanized
steel sheet pieces of Experimental example 6. The obtained
composites were annealed at 170.degree. C. for 1 hour. In the
experiment there was used a PPS resin composition comprising only a
filler and PPS containing only a very small amount of polyolefin
polymer. One day later, 10 of the composites were subjected to a
tensile test. The average shear rupture strength was 7.5 MPa. The
difference in the materials of the resin composition that was used
accounted for the considerably poorer results as compared with
those of Experimental example 8.
Experimental Example 10
Injection Bonding
[0183] An experiment was conducted in the same way as in
Experimental example 8, but using herein the PPS composition (3)
obtained in Preparative example 3 instead of the PPS composition
(1) obtained in Preparative example 1. Composites were obtained
through injection bonding using the surface-treated galvanized
steel sheet pieces of Experimental example 6. The obtained
composites were annealed for 1 hour at 170.degree. C. on the day of
molding. Two days later, the shear rupture strength of the
composites was measured in a tensile tester, which yielded an
average of 20.0 MPa.
Experimental Example 11
Injection Bonding: Comparative Example
[0184] An experiment was conducted in the same way as in
Experimental example 8, but using herein the PPS composition (4)
obtained in Preparative example 4 instead of the PPS composition
(1) obtained in Preparative example 1. Composites were obtained
through injection bonding using the surface-treated galvanized
steel sheet pieces of Experimental example 6. In the experiment
there was used a PPS resin composition containing a substantial
amount of polyolefin polymer. However, a large amount of gas was
generated during molding, and thus molding was discontinued. The
main component of the resin composition in this experiment was not
PPS.
Experimental Example 12
Injection Bonding
[0185] Injection bonding was carried out using the PBT composition
(1) obtained in Preparative example 5 and the surface-treated
galvanized steel sheet pieces from Experimental example 6.
Specifically, the galvanized steel sheet pieces were inserted in an
injection mold. The mold was closed and the PBT composition (1)
obtained in Preparative example 5 was injected at an injection
temperature of 280.degree. C. The mold temperature was 140.degree.
C. The above injection bonding yielded 20 composites illustrated in
FIG. 2. The size of the resin portion was 10 mm.times.45 mm.times.5
mm. The adhesion area was 10 mm.times.5 mm=0.5 cm.sup.2. The
composites were annealed on the same day of molding, in a hot-air
dryer at 150.degree. C. for 1 hour. One day later, the composites
were tested in a tensile tester, which yielded a three-piece
average shear rupture strength of 19.0 MPa.
Experimental Example 13
Injection Bonding: Comparative Example
[0186] Composites were obtained by injection bonding in exactly the
same way as in Experimental example 12, but using herein a
commercially available PBT resin "Toraycon 1101G30 (by Toray)",
containing 30% of glass fibers, instead of the PBT composition (1)
obtained in Preparative example 5. The obtained composites were
annealed at 150.degree. C. for 1 hour. In the present example there
is used a PBT resin composition comprising only a filler plus PBT
containing no polymer that elicits injection bonding. One day later
the composites were tested using a tensile tester to measure shear
rupture strength. The resulting average shear rupture strength was
low, of 9.2 MPa, significantly inferior to that of Experimental
example 12.
Experimental Example 14
Injection Bonding
[0187] Composites were obtained by injection bonding in exactly the
same way as in Experimental example 12, but using herein the PBT
composition (2) obtained in Preparative example 6 instead of the
PBT composition (1) obtained in Preparative example 5. The obtained
composites were annealed on the same day of molding at 150.degree.
C. for 1 hour. Two days later, the composites were tested using a
tensile tester to measure shear rupture strength, which averaged
18.7 MPa.
Experimental Example 15
Injection Bonding
[0188] Composites were obtained by injection bonding in exactly the
same way as in Experimental example 12, but using herein the PBT
composition (3) obtained in Preparative example 7 instead of the
PBT composition (1) obtained in Preparative example 5. The obtained
composites were annealed on the same day of molding at 150.degree.
C. for 1 hour. Two days later, the composites were tested using a
tensile tester to measure shear rupture strength, which averaged
18.1 MPa.
Experimental Example 16
Injection Bonding: Comparative Example
[0189] The surface-treated galvanized steel sheet pieces in
Experimental example 2 were taken out, were picked up using gloves,
to prevent adhesion of grease or the like, and were inserted into
an injection mold. The mold was closed and the PPS composition (1)
obtained in Preparative example 1 was injected at an injection
temperature of 310.degree. C. The mold temperature was 140.degree.
C. Specifically, injection bonding was carried out in exactly the
same way as in Experimental example 8, but herein the used
galvanized steel sheet pieces were surface-treated as in
Experimental example 2, and not as in Experimental example 6. The
composites obtained in above injection bonding were annealed for 1
hour in a hot-air dryer at 170.degree. C. One day later the
composites were tested using a tensile tester to measure shear
rupture strength. The resulting average shear rupture strength was
a mere 9.8 MPa, significantly inferior to that of Experimental
example 8.
Experimental Example 17
Injection Bonding
[0190] The PPS composition (1) was injection-bonded in exactly the
same way as in Experimental example 8, but using herein the
surface-treated galvanized steel sheet pieces of Experimental
example 1 instead of the surface-treated galvanized steel sheet
pieces of Experimental example 6. The composites obtained through
the above injection bonding were annealed in a hot-air dryer at
170.degree. C. for 1 hour. One day later, the composites were
tested in a tensile tester, which yielded an average shear rupture
strength of 18.8 MPa.
Experimental Example 18
Injection Bonding
[0191] The PPS composition (1) was injection-bonded in exactly the
same way as in Experimental example 8, but using herein the
surface-treated galvanized steel sheet pieces of Experimental
example 3 instead of the surface-treated galvanized steel sheet
pieces of Experimental example 6. The composites obtained through
the above injection bonding were annealed in a hot-air dryer at
170.degree. C. for 1 hour. One day later, the composites were
tested in a tensile tester, which yielded a three-piece average
shear rupture strength of 22.5 MPa.
Experimental Example 19
Injection Bonding
[0192] The PPS composition (1) was injection-bonded in exactly the
same way as in Experimental example 8, but using herein the
surface-treated galvanized steel sheet pieces of Experimental
example 4 instead of the surface-treated galvanized steel sheet
pieces of Experimental example 6. The composites obtained through
the above injection bonding were annealed in a hot-air dryer at
170.degree. C. for 1 hour. One day later, the composites were
tested in a tensile tester, which yielded an average shear rupture
strength of 21.5 MPa.
Experimental Example 20
Injection Bonding
[0193] The PPS composition (1) was injection-bonded in exactly the
same way as in Experimental example 8, but using herein the
surface-treated galvanized steel sheet pieces of Experimental
example 5 instead of the surface-treated galvanized steel sheet
pieces of Experimental example 6. The composites obtained through
the above injection bonding were annealed in a hot-air dryer at
170.degree. C. for 1 hour. One day later, the composites were
tested in a tensile tester, which yielded an average shear rupture
strength of 19.5 MPa.
Experimental Example 21
Injection Bonding
[0194] The PPS composition (1) was injection-bonded in exactly the
same way as in Experimental example 8, but using herein the
surface-treated zinc-aluminum alloy coated steel sheet pieces of
Experimental example 7 instead of the surface-treated galvanized
steel sheet pieces of Experimental example 6. The composites
obtained through the above injection bonding were annealed in a
hot-air dryer at 170.degree. C. for 1 hour. One day later, the
composites were tested in a tensile tester, which yielded an
average shear rupture strength of 24.8 MPa.
Experimental Example 22
Injection Bonding
[0195] The surface-treated zinc-aluminum alloy coated steel sheet
pieces in Experimental example 7 were taken out, were picked up
using gloves, to prevent adhesion of grease or the like, and were
inserted into an injection mold. The mold was closed and the PBT
composition (1) obtained in Preparative example 5 was injected at
an injection temperature of 280.degree. C. The mold temperature was
140.degree. C. The above injection bonding yielded 20 composites
illustrated in FIG. 2. The size of the resin portion was 10
mm.times.45 mm.times.5 mm. The adhesion area was 10 mm.times.5
mm=0.5 cm.sup.2. The composites were annealed on the same day of
molding, in a hot-air dryer at 150.degree. C. for 1 hour. One day
later, the composites were tested in a tensile tester, which
yielded an average shear rupture strength of 23.8 MPa.
Experimental Example 23
Injection Bonding: Comparative Example
[0196] The hot-dip zinc-aluminum alloy coated steel sheet
"GL-AZ150" used in Experimental example 7 was cut into 18
mm.times.45 mm rectangular pieces to yield a plurality of
zinc-aluminum alloy coated steel sheet pieces. The zinc-aluminum
alloy coated steel sheet pieces were immersed at 65.degree. C. for
7 minutes in a 7.5% aqueous solution of a degreasing agent for
aluminum "NE-6", and were rinsed with water. The PBT composition
(1) was injection-bonded in exactly the same way as in Experimental
example 20, but using herein zinc-aluminum alloy coated steel sheet
pieces subjected to only the degreasing treatment, instead of the
surface-treated galvanized steel sheet pieces of Experimental
example 5. The composites obtained through the above injection
bonding were annealed at 150.degree. C. for 1 hour. One day later,
10 of the composites were subjected to a tensile test, to measure
the shear rupture strength. However, seven of the composites broke
during the operation of the tensile jig, while the average shear
rupture strength of the remaining three composites was extremely
low, of 2.1 MPa.
Experimental Example 24
Manufacture of an Injection Molded Article
[0197] An injection molded article having the shape illustrated in
FIG. 3 and FIG. 4 was manufactured using (five types given in Table
1): 1. a PBT resin containing 30% of glass fibers "Toraycon
1101G30"; 2. the PBT composition (3) having, as main components,
the PBT obtained in Preparative example 7, PET and a polyolefin; 3.
the PPS composition (1) obtained in Preparative example 1; 4. a 6
nylon resin "B3EG7 (by BASF)" comprising 30% of glass fibers; and
5. an aromatic polyamide resin "Amilan CM3510G30 (by Toray)"
comprising 30% of glass fibers. The runner portion (protruding
portion extending from the gate to the main body) of the obtained
molded article was cut from the base using a nipper, and was
subjected to the following experiment.
Experimental Example 25
Press-Fusion Bonding Experiment
[0198] An injection molded article 22 prepared in Experimental
example 24 was wedged in the heat-insulating material 20 of the jig
upper die 19 of the jig system illustrated in FIG. 5. Meanwhile,
the 0.4 mm-thick hot-dip galvanized steel sheet used in
Experimental example 6 was cut into 40 mm.times.60 mm pieces, to
yield galvanized steel sheet pieces having the shape illustrated in
FIG. 6. The galvanized steel sheet pieces were subjected to exactly
the same surface treatment as in Experimental example 6. After the
surface treatment, the galvanized steel sheet pieces were heated in
a hot plate, were clamped with a pin set, and were set in the
recess of the heat-insulating material 12 of the jig lower die 11
illustrated in FIG. 5. The vacuum pump 26 was driven, the jig upper
die 19 and the jig lower die 11 were pressed together, and the
two-way stopcock 28 was opened. The interior is held at about
several mmHg for several to 5 seconds, and the bottom of the resin
molded article 22 melts, whereupon the four-way stopcock 27 is
turned 90 degrees, to thereby revert the interior of the system to
normal pressure.
[0199] It is important to adjust the process in such a manner that
the bottom of the resin molded article is kept in a molten state
for about ten seconds, depending on the heating temperature and the
size (thermal capacity) of the galvanized steel sheet piece. As a
result of the above series of operations, the molten resin
infiltrates into the micron-scale recesses of the metal alloy
surface, and part of the molten resin gets into the ultra-fine
irregularities. This gives rise to strong bonding thereafter
through crystallization and solidification. The composite
illustrated in FIG. 7 is obtained as a result. The composite was
annealed in a hot-air dryer at 150.degree. C. for 1 hour, and was
then cooled. After 1 week, the resin molded article 31 was gripped
by the chucks 36 of a tensile tester, as illustrated in FIG. 8 (a)
or FIG. 8 (b). With the galvanized steel sheet piece in a fixed
state, the resin molded article 31 was pulled (through application
of pulling external force) until breakage. The force upon breakage
was measured. The results obtained in experiments carried out with
respective resin molded articles are given in Table 1
("Experimental example 25"). The specimens that broke at 30 kgF or
less were rated as poor (x), while the specimens that did not break
were rated as good (O). None of the above-described five types of
resin molded article broke at 30 kgF or less. Therefore, the
press-fusion bonding method according to the present invention is
found to elicit strong bonding between a galvanized steel sheet and
a resin molded article.
Experimental Example 26
Press-Fusion Bonding Experiment: Comparative Example
[0200] Herein, the 0.4 mm-thick hot-dip galvanized steel sheet used
in Experimental example 6 was cut into 40 mm.times.60 mm pieces, to
yield galvanized steel sheet pieces having the shape illustrated in
FIG. 6. The galvanized steel sheet pieces were subjected to exactly
the same surface treatment as in Experimental example 2. In this
case, however, only light degreasing was carried out. A
press-fusion bonding test identical to that of Experimental example
25 was carried out using galvanized steel sheet pieces after the
surface treatment. The results are given in Table 1 ("Experimental
example 26"). As might have been expected, the galvanized steel
sheet piece and the resin molded article did not bond, or the
bonding strength was very low, and the five types broke at 30 kgF
or less.
TABLE-US-00001 TABLE 1 Results of press-fusion bonding experiments
on galvanized steel sheets Heating Experimental Experimental Resin
type temperature example 25 example 26 PBT Toraycon "1101G30"
300.degree. C. .smallcircle. x PBT/PET/polyolefin 300.degree. C.
.smallcircle. x PPS/polyolefin/compatibilizer 330.degree. C.
.smallcircle. x PA6 (B3EG7) 330.degree. C. .smallcircle. x Aromatic
polyamide (Amilan 300.degree. C. .smallcircle. x CM3501G30)
Experimental Example 27
Adhesion
[0201] The ends of the surface-treated galvanized steel sheet
pieces of Experimental examples 1, 3, 5 and 6 were coated with an
epoxy adhesive "EP 106 (by Cemedine)", and were placed in a
desiccator. The desiccator was depressurized to an inner pressure
of 3 mmHg using a vacuum pump. The pressure was reverted to normal
pressure after two minutes in a reduced-pressure state. The
operation of reverting to normal pressure after depressurization
was carried out a total three times, and then the galvanized steel
sheet pieces were removed from the desiccator. The surface-treated
galvanized steel sheet pieces were stacked onto each other and were
fixed, in the manner illustrated in FIG. 11, with clips. The
adhesion area therebetween was 0.6 to 0.7 cm.sup.2. These fixed
assemblies were heated in a hot-air dryer. Specifically, the
assembly was kept at 100.degree. C. for 1 hour and then the
temperature was raised to 135.degree. C. and was held there for 40
minutes. Thereafter, the temperature was further raised to
165.degree. C. and was held there for 30 minutes. The bonded body
obtained after cooling was left to stand for one week, after which
the bonded body was tested to failure using a tensile tester, to
measure the average shear rupture strength. The results are given
in Table 2. In all cases the adhesive strength was extremely high,
of about 40 MPa.
Experimental Example 28
Adhesion: Comparative Example
[0202] An experiment was carried out in exactly the same way as in
Experimental example 27, but using herein the surface-treated
galvanized steel sheet pieces of Experimental example 2. The
measured shear rupture strength is given in Table 2. The shear
rupture strength in the present experimental example was 25 MPa,
which is inferior to the adhesive strength in all instances of
Experimental example 27. This showed that bonding strength is
enhanced when the epoxy adhesive penetrates into the irregularities
and ultra-fine irregularities of the micron-scale roughness, and
solidifies in that state within the irregularities.
TABLE-US-00002 TABLE 2 Joining using an epoxy adhesive "EP 106 (by
Cemedine)" Experimental Surface Conversion Average shear example
treatment coating type rupture strength Experimental Experimental
Chromate 39 MPa example 27 example 1 (details unclear) Experimental
Experimental Zinc phosphate 38 MPa example 27 example 3
Experimental Experimental Zinc calcium 37 MPa example 27 example 5
phosphate Experimental Experimental Chromate 40 MPa example 27
example 6 Experimental Experimental Chromate, but 25 MPa example 28
example 2 mostly hidden
Experimental Example 29
Adhesion
[0203] The ends of the surface-treated zinc-aluminum alloy coated
steel sheet pieces of Experimental example 7 were coated with an
epoxy adhesive "EP 106", and were placed in a desiccator. The
desiccator was depressurized to an inner pressure of 3 mmHg using a
vacuum pump. The pressure was reverted to normal pressure after two
minutes in a reduced-pressure state. The operation of reverting to
normal pressure after depressurization was carried out a total
three times, and then the zinc-aluminum alloy coated steel sheet
pieces were removed from the desiccator. The removed zinc-aluminum
alloy coated steel sheet pieces were stacked onto each other and
were fixed, in the manner illustrated in FIG. 11, with clips. The
adhesion area therebetween was 0.6 to 0.7 cm.sup.2. These fixed
assemblies were heated in a hot-air dryer. Specifically, the
temperature was raised to 135.degree. C. and was held there for 40
minutes. Thereafter, the temperature was further raised to
165.degree. C. and was held there for 30 minutes. The bonded body
obtained after cooling was left to stand for one week, after which
the bonded body was tested to failure using a tensile tester, to
measure the average shear rupture strength. The adhesive strength,
averaged for 3 sets, was very high, of 41 MPa.
Experimental Example 30
Adhesion: Comparative Example
[0204] A 0.6 mm-thick hot-dip zinc-aluminum alloy coated steel
sheet (commonly referred to as galvalume steel sheet) "GL-AZ150"
was cut into 18 mm.times.45 mm rectangular pieces, to prepare
zinc-aluminum alloy coated steel sheet pieces. The pieces were
immersed for 5 minutes in the same degreasing bath as used in
Experimental example 7, were thoroughly rinsed with water, and were
dried at 90.degree. C. for 15 minutes. The ends of these
zinc-aluminum alloy coated steel sheet pieces, having only been
degreased, were coated with an epoxy adhesive "EP 106", and were
placed in a desiccator. The desiccator was depressurized to an
inner pressure of 3 mmHg using a vacuum pump. The pressure was
reverted to normal pressure after two minutes in a reduced-pressure
state. The operation of reverting to normal pressure after
depressurization was carried out a total three times, and then the
zinc-aluminum alloy coated steel sheet pieces were removed from the
desiccator. The removed zinc-aluminum alloy coated steel sheet
pieces were stacked onto each other and were fixed, in the manner
illustrated in FIG. 11, with clips. The adhesion area therebetween
was 0.6 to 0.7 cm.sup.2. These fixed assemblies were heated in a
hot-air dryer. Specifically, the temperature was raised to
135.degree. C. and was held there for 40 minutes. Thereafter, the
temperature was further raised to 165.degree. C. and was held there
for 30 minutes. The bonded body obtained after cooling was left to
stand for one week, after which the bonded body was tested to
failure using a tensile tester, to measure the average shear
rupture strength. The adhesive strength averaged over 3 sets was
strong, of 28 MPa, but significantly inferior to that of
Experimental example 29. This showed that bonding strength is
enhanced when the epoxy adhesive penetrates into the irregularities
and ultra-fine irregularities of the micron-scale roughness, and
solidifies in that state within the irregularities.
Experimental Example 31
Preparation of CFRP Prepreg
[0205] A thermosetting resin according to Table 3 was prepared in
order to produce the CFRP prepreg.
TABLE-US-00003 TABLE 3 Thermosetting resin for prepreg Proportion
(parts by Resin fraction weight) Epoxy Brominated bisphenol A solid
epoxy 10.0 resin resin "EPC-152 (by Dainippon Ink & Chemicals)"
Bisphenol A liquid epoxy resin "EP- 13.9 828 (by Yuka-Shell Epoxy)"
Bisphenol F liquid epoxy resin "EPC- 24.8 830 (by Dainippon Ink
& Chemicals)" Elastomer Weakly crosslinked carboxyl- 8.0
terminated solid acrylonitrile butadiene rubber "DN-611 (by Zeon
Corporation)" Thermoplastic hydroxyl-terminated 3.0 polyether
sulfone "PES-100P (by Mitsui Toatsu Chemicals)" Curing agent
Tetraglycidyldiaminodiphenylmethane "ELM-434 15.0 (by Sumitomo
Chemical)" 4,4'-diaminodiphenyl sulfone "4,4'-DDS (by 25.0 Sumitomo
Chemical)" BF.sub.3-monoethylamine complex "BF.sub.3.cndot.MEA" 0.3
Total 100.0
[0206] A thermosetting resin having the composition of Table 3 was
blended at normal temperature and was rolled into a sheet shape.
The obtained thermosetting resin film was set in a prepreg machine,
and was pressure-bonded from both sides of unidirectionally aligned
carbon fibers "T-300 (by Toray)", as reinforcing fibers, under
application of pressure in accordance with known methods, to
prepare a CFRP prepreg having a resin content adjusted to 38% and a
fiber areal weight of 190 g/m.sup.2.
Experimental Example 32
Production of a Composite
[0207] The ends of the surface-treated galvanized steel sheet
pieces of Experimental example 6 were coated with the same epoxy
adhesive "EP 106" of Experimental example 27. The pieces were
placed in a desiccator and the operation of reverting to normal
pressure after depressurization was carried out a total three
times. Composites of CFRP pieces and the galvanized steel sheet
pieces were prepared using the above-described baking jig 41
illustrated in FIG. 9. Carbon fibers "T-300" cut separately were
overlaid on the end of a galvanized steel sheet piece 51, as in
FIG. 9, having been subjected to depressurization/return to normal
pressure over three times. An epoxy adhesive "EP-106", discharged
out of a syringe, was coated onto the "T-300". A second ply of
"T-300" was overlaid thereon, the same adhesive was applied, a
further third ply of "T-300" was overlaid thereon, and the same
adhesive was applied. The result was a stack of three plies of
carbon fibers impregnated with epoxy adhesive (denoted by the
reference numeral 52 in FIG. 9). The adhesive "EP-106" was used in
an amount of about 1 cc.
[0208] The spacer 53 is wedged in the space between the inner wall
face of the mold body 42 and the carbon fibers thus stacked. The
demolding film 54 is laid so as to cover the spacer 53 and the
stacked carbon fibers. A PTFE block 55 of PTFE
(polytetrafluoroethylene resin) is placed, as a weight, on the
demolding film 54. A weight 58 of 0.5 kg is further placed thereon.
In this state, the entire baking jig was placed in a hot-air dryer.
The dryer was powered, the temperature was raised to 100.degree. C.
and was left there for 1 hour. Next, the temperature was raised to
135.degree. C., heating proceeded at that temperature for 40
minutes, and then the temperature was raised to 165.degree. C. over
5 minutes. The temperature was held at 165.degree. C. for 1 hour,
was raised to 180.degree. C., was held there for 20 minutes, and
then the dryer was powered off and was left to cool with the door
closed. On the next day, the baking jig 1 was removed from the
dryer and the composite 50 of the galvanized steel sheet pieces and
the CFRP piece was demolded. The same operation was repeated to
obtain four sets of composites 50.
[0209] On the second day after bonding, the four composites were
measured for shear rupture strength using a tensile tester. The
CFRP portion was sandwiched between two pieces of
sandpaper-roughened 1 mm-thick SUS304 stainless steel pieces. The
resulting stack was clamped and fixed between chuck plates. The
average shear rupture strength of four sets was very high, of 35
MPa.
Experimental Example 33
Production of a Composite
[0210] The ends of the surface-treated galvanized steel sheet
pieces of Experimental example 6 were coated with the same epoxy
adhesive "EP 106" of Experimental example 27. The pieces were
placed in a desiccator and the operation of reverting to normal
pressure after depressurization was carried out a total three
times. Composites of CFRP pieces (cured CFRP prepreg prepared in
Experimental example 31) and the galvanized steel sheet pieces were
prepared using the above-described baking jig 41 illustrated in
FIG. 9. Three plies of the CFRP prepreg prepared in Experimental
example 31 were overlaid (reference numeral 52 in FIG. 9) on the
ends of a galvanized steel sheet piece 51 having been subjected to
three operations of depressurization/reverting to normal pressure
in FIG. 9.
[0211] A spacer 53 is wedged in the space between the inner wall
face of the mold body 42 and the CFRP prepreg thus stacked. The
demolding film 54 is laid so as to cover the spacer 53 and the
stacked CFRP prepreg. A PTFE block 55 of PTFE
(polytetrafluoroethylene resin) is placed, as a weight, on the
demolding film 54. A weight 58 of 0.5 kg is further placed thereon.
In this state, the entire baking jig was placed in a hot-air dryer.
The dryer was powered, the temperature was raised to 100.degree. C.
and was left there for 1 hour. Next the temperature was raised to
135.degree. C., heating proceeded at that temperature for 1 hour,
and then the temperature was raised to 165.degree. C. and left
there for 1 hour. The temperature was raised to 180.degree. C., was
held there for 20 minutes, and then the dryer was powered off and
was left to cool with the door closed. On the next day, the baking
jig 1 was removed from the dryer and the composite 50 of the
galvanized steel sheet pieces and the CFRP piece (cured product of
three plies of CFRP prepreg) was demolded. The same operation was
repeated to obtain four sets of composites 50.
[0212] On the second day after bonding, the four composites were
measured for shear rupture strength using a tensile tester. The
CFRP portion was sandwiched between two pieces of
sandpaper-roughened 1 mm-thick SUS304 stainless steel pieces. The
resulting stack was clamped and fixed between chuck plates. The
average shear rupture strength for four sets was very high, of 33
MPa.
Experimental Example 34
Adhesion
[0213] An adhesive was obtained by thoroughly mixing 10 g of
commercially available vinyl ester unsaturated polyester "Ripoxy
R802 (by Showa High Polymer)" for GFRP and 0.1 g of t-butyl
peroxybenzoate "Perbutyl Z (by Nippon Oil and Fats)". The ends of
the surface-treated galvanized steel sheet pieces of Experimental
example 6 were coated with the obtained adhesive, and were placed
in a desiccator. The desiccator was depressurized to an inner
pressure not higher than 50 mmHg using a vacuum pump. This
reduced-pressure state was held for several seconds, and then the
pressure was reverted to normal pressure. The operation of
reverting to normal pressure after depressurization was carried out
a total three times, and then the galvanized steel sheet pieces
were removed from the desiccator. The removed galvanized steel
sheet pieces were stacked onto each other and were fixed, in the
manner illustrated in FIG. 11, with clips, to prepare three sets.
The adhesion area therebetween was 0.6 to 0.7 cm.sup.2. These fixed
assemblies were heated in a hot-air dryer. Specifically, the
temperature was raised to 90.degree. C. and was held there for 1
hour. Thereafter, the temperature was further raised to 120.degree.
C. and was held there for 1 hour. The bonded body obtained after
cooling was left to stand for one week, after which the bonded body
was tested to failure using a tensile tester, to measure the
average shear rupture strength. The strength was very high, of 27
MPa.
INDUSTRIAL APPLICABILITY
[0214] The present invention provides a technology for strongly
bonding galvanized steel sheets, which are used as ordinary
construction materials having good corrosion-resistance and
post-workability, with resin molded articles, FRP and metal alloys.
The composite of an adherend and a galvanized steel sheet according
to the present invention, and the method for manufacturing the
composite, are useful in particular in the field of construction
materials.
* * * * *