U.S. patent application number 13/087500 was filed with the patent office on 2011-12-08 for aluminum alloy-and-resin composite and method for making the same.
This patent application is currently assigned to HON HAI PRECISION INDUSTRY CO., LTD.. Invention is credited to CHENG-SHI CHEN, WEN-RONG CHEN, HUANN-WU CHIANG, YUAN-YUAN FENG, KE HUANG, CHI LAI, LI-MING SHEN, DAI-YU SUN.
Application Number | 20110297549 13/087500 |
Document ID | / |
Family ID | 45050653 |
Filed Date | 2011-12-08 |
United States Patent
Application |
20110297549 |
Kind Code |
A1 |
CHEN; WEN-RONG ; et
al. |
December 8, 2011 |
ALUMINUM ALLOY-AND-RESIN COMPOSITE AND METHOD FOR MAKING THE
SAME
Abstract
An aluminum alloy-and-resin composite includes an aluminum alloy
substrate, an anodic oxide film formed on the substrate, and resin
composition bonded with the anodic oxide film. The anodic oxide
film has nano-pores with an average diameter of about 30-60 nm. The
resin composition fills the nano-pores and coatings surfaces of the
anodic oxide film. The resin composition contains crystalline
thermoplastic synthetic resins.
Inventors: |
CHEN; WEN-RONG; (Tu-Cheng,
TW) ; CHIANG; HUANN-WU; (Tu-Cheng, TW) ; CHEN;
CHENG-SHI; (Tu-Cheng, TW) ; SUN; DAI-YU;
(Shenzhen City, CN) ; FENG; YUAN-YUAN; (Shenzhen
City, CN) ; HUANG; KE; (Shenzhen City, CN) ;
LAI; CHI; (Shenzhen City, CN) ; SHEN; LI-MING;
(Shenzhen City, CN) |
Assignee: |
HON HAI PRECISION INDUSTRY CO.,
LTD.
Tu-Cheng
TW
HONG FU JIN PRECISION INDUSTRY (ShenZhen) CO., LTD.
Shenzhen City
TW
|
Family ID: |
45050653 |
Appl. No.: |
13/087500 |
Filed: |
April 15, 2011 |
Current U.S.
Class: |
205/50 ;
205/106 |
Current CPC
Class: |
C23F 1/36 20130101; C08L
81/02 20130101; C09D 167/02 20130101; C25D 11/16 20130101; B29C
45/14311 20130101; C23C 22/46 20130101; C25D 11/18 20130101; C08K
7/28 20130101; B29K 2705/02 20130101; C23C 22/83 20130101; B29C
2045/14868 20130101; C23C 22/08 20130101 |
Class at
Publication: |
205/50 ;
205/106 |
International
Class: |
C25D 11/04 20060101
C25D011/04; C25D 11/18 20060101 C25D011/18; C25D 11/16 20060101
C25D011/16 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 4, 2010 |
CN |
201010192062.9 |
Claims
1. An aluminum alloy-and-resin composite, comprising: an aluminum
alloy substrate with an anodic oxide film having nano-pores with an
average diameter of about 30-60 nm on its surface; and resin
composition integrally bonded to the surface of the aluminum alloy
substrate having the anodic oxide film, the resin composition
filling the nano-pores of the anodic oxide film, the resin
composition containing crystalline thermoplastic synthetic
resins.
2. The composite as claimed in claim 1, wherein the resin
composition is formed by molding crystalline thermoplastic
synthetic resin on the anodic oxide film.
3. The composite as claimed in claim 1, wherein the crystalline
thermoplastic synthetic resin is polyphenylene sulfide, polyamide,
polyethylene terephthalate, or polybutylene terephthalate.
4. The composite as claimed in claim 3, wherein the crystalline
thermoplastic synthetic resin is polyphenylene sulfide added with
fiberglass, the fiberglass has a mass percentage of about
10-50%.
5. A method for making an aluminum alloy-and-resin composite,
comprising: providing an aluminum alloy substrate; roughening the
surface of the substrate; anodizing the substrate to form an anodic
oxide film on the substrate, the anodic oxide film defining
nano-pores having an average diameter of about 30-60 nm;
positioning the anodized substrate in a mold and molding
crystalline thermoplastic synthetic resin on the anodic oxide film
and filling the nano-pores of the anodic oxide film to form the
composite.
6. The method as claimed in claim 5, wherein roughening the
substrate includes the step of dipping the substrate in an alkaline
solution having a temperature of about 40-55.degree. C. for about
1-2 minutes.
7. The method as claimed in claim 6, wherein the alkaline solution
includes sodium hydroxide having a concentration of about 20-35
g/L, and sodium carbonate having a concentration of about 20-30
g/L.
8. The method as claimed in claim 5, wherein anodizing the
substrate is carried out in a sulfuric acid solution for about
15-60 minutes, the concentration of the sulfuric acid is about
100-250 ml/L, the electric current density through the sulfuric
acid solution is about 0.5-4.9 A/dm.sup.2.
9. The method as claimed in claim 5, wherein anodizing the
substrate is carried out in a phosphoric acid solution or an oxalic
acid solution.
10. The method as claimed in claim 5, wherein the crystalline
thermoresin is polyphenylene sulfide, polyamide, polyethylene
terephthalate, or polybutylene terephthalate.
11. The method as claimed in claim 10, wherein the crystalline
thermoplastic synthetic resin is polyphenylene sulfide added with
fiberglass, the fiberglass has a mass percentage of about
10-50%.
12. The method as claimed in claim 5, further comprising a step of
degreasing the substrate before roughening the substrate.
13. The method as claimed in claim 12, wherein degreasing the
substrate comprises dipping the substrate in a sodium salt
solution.
14. The method as claimed in claim 13, wherein the sodium salt
solution includes sodium carbonate having a concentration of about
30-50 g/L, sodium phosphate having a concentration of about 30-50
g/L, and sodium silicate having a concentration of about 3-5
g/L.
15. An aluminum alloy-and-resin composite, comprising: an aluminum
alloy substrate; an anodic oxide film having nano-pores with an
average diameter of about 30-60 nm formed on a surface of the
substrate, and resin composition integrally molded on the surface
of the aluminum alloy substrate having the anodic oxide film, the
resin composition filling the nano-pores of the anodic oxide film,
the resin composition containing crystalline thermoplastic
synthetic resins.
16. The composite as claimed in claim 15, wherein the anodic oxide
film and the nano-pores are formed by roughing and anodizing the
substrate.
17. The composite as claimed in claim 16, wherein roughing the
substrate comprising the step of chemically etching the
substrate.
18. The composite as claimed in claim 17, wherein chemically
etching the substrate includes the step of dipping the substrate in
an alkaline solution having a temperature of about 40-55.degree. C.
for about 1-2 minutes.
19. The composite as claimed in claim 18, wherein the alkaline
solution includes sodium hydroxide having a concentration of about
20-35 g/L, and sodium carbonate having a concentration of about
20-30 g/L.
20. The composite as claimed in claim 15, wherein the crystalline
thermoplastic synthetic resin is polyphenylene sulfide, polyamide,
polyethylene terephthalate, or polybutylene terephthalate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is one of the two related co-pending U.S.
patent applications listed below. All listed applications have the
same assignee. The disclosure of each of the listed applications is
incorporated by reference into another listed application.
TABLE-US-00001 Attorney Docket No. Title Inventors US 33056
ALUMINUM ALLOY-AND-RESIN WEN-RONG COMPOSITE AND METHOD CHEN et al.
FOR MAKING THE SAME US 33709 ALUMINUM ALLOY-AND-RESIN WEN-RONG
COMPOSITE AND METHOD CHEN et al. FOR MAKING THE SAME
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to composites of aluminum
alloy and resin, particularly to an aluminum alloy-and-resin
composite having high bonding strength between aluminum alloy and
resin and a method for making the composite.
[0004] 2. Description of Related Art
[0005] Adhesives, for combining heterogeneous materials in the form
of a metal (such as light metals) and a synthetic resin are
demanded in a wide variety of technical fields and industries, such
as the automotive and household appliance fields. However,
adhesives are generally only effective in a narrow temperature
range of about -50.degree. C. to about 100.degree. C., which means
they are not suitable in applications where operating or
environmental temperatures may fall outside the range.
[0006] Therefore, other bonding methods have been applied that do
not involve the use of an adhesive. One example of such methods is
by forming bonds through injection molding or other similar
process. However, the bonding strength of the metal and resin can
be improved.
[0007] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE FIGURES
[0008] Many aspects of the aluminum alloy-and-resin composite can
be better understood with reference to the following figures. The
components in the figures are not necessarily drawn to scale, the
emphasis instead being placed upon clearly illustrating the
principles of the aluminum alloy-and-resin composite. Moreover, in
the drawings like reference numerals designate corresponding parts
throughout the several views.
[0009] FIG. 1 is a cross-section view of an exemplary embodiment of
a composite of anodized aluminum alloy and resin.
[0010] FIG. 2 is a scanning electron microscopy view of an
exemplary embodiment of the anodized aluminum alloy.
[0011] FIG. 3 is a scanning electron microscopy cross-section view
of the composite shown in FIG. 1.
[0012] FIG. 4 is a cross-section view of molding the composite
shown in FIG. 1.
DETAILED DESCRIPTION
[0013] FIG. 1 shows an aluminum alloy-and-resin composite 100
according to an exemplary embodiment. The aluminum alloy-and-resin
composite 100 includes an aluminum alloy substrate 11, an anodic
oxide film 13 formed on a surface of the aluminum alloy substrate
11, and resin compositions 15 formed on the anodic oxide film
13.
[0014] The anodic oxide film 13 is formed by anodizing the aluminum
alloy substrate 11. Referring to FIG. 2, the anodic oxide film 13
defines nano-pores 131. These nano-pores 131 have an average
diameter of 30-60 nm. The nano-pores 131 are symmetrically
distributed in the anodic oxide film 13.
[0015] The resin composition 15 may be coupled to the anodic oxide
film 13 by molding. During the molding process, molten resin coats
surfaces of the anodic oxide film 13 and fills the nano-pores 131,
thus strongly bonding the resin composition 15 to the anodic oxide
film 13. Compared to the conventional injection molding process
using non-anodic film, the composite 100 in this exemplary
embodiment has a much stronger bond between the resin composition
15 and the substrate 11 (about quintuple bonding force). The resin
composition 15 may be made up of crystalline thermoplastic
synthetic resins having high fluidity. In this exemplary
embodiment, polyphenylene sulfide (PPS), polyamide (PA),
polyethylene terephthalate (PET), and polybutylene terephthalate
(PBT) can be selected as the molding materials for the resin
composition 15, and all of the resins can bond firmly with the
anodic oxide film 13 and the substrate 11.
[0016] It is to be understood that auxiliary components may be
added to the resins to modify properties of the composition 15, for
example, fiberglass may be added to PPS. The fiberglass may have a
mass percentage of about 10-50%.
[0017] FIG. 3 shows a scanning electron microscopy cross-sectional
view of the composite 100. In FIG. 3, almost no cracks are observed
between the resin composition 15 and the anodic oxide film 13,
clearly demonstrating that the resin composition 15 tightly bonds
to the anodic oxide film 13 and fills the nano-pores 131.
[0018] A method for making the composite 100 may include the
following steps:
[0019] The aluminum alloy substrate 11 is provided.
[0020] The substrate 11 is degreased. The degreasing process may
include the step of dipping the substrate 11 in a sodium salt
solution for about 5-15 minutes. The sodium salt solution may
include sodium carbonate having a concentration of about 30-50
grams per liter (g/L), sodium phosphate having a concentration of
about 30-50 g/L, and sodium silicate having a concentration of
about 3-5 g/L. The temperature of the sodium salt solution may be
about 50-60.degree. C. Once degreased, the substrate 11 is removed
from the sodium salt solution and rinsed in water.
[0021] The surface of the substrate 11 is roughened. Roughening the
substrate 11 may include the step of chemically etching. The
chemical etching process may include the step of dipping the
substrate 11 in an alkaline solution for about 1-2 minutes. The
alkaline solution may include sodium hydroxide having a
concentration of about 20-35 g/L, and sodium carbonate having a
concentration of about 20-30 g/L. The temperature of the alkaline
solution may be about 40-55.degree. C. The chemical etching process
roughens the surface of the substrate 11 so that it will be more
uniformly anodized and to obtain a narrower range of diameters of
the nano-pores 131 of the anodic oxide film 13. Next, the substrate
11 is removed from the alkaline solution and rinsed in water.
[0022] The substrate 11 is anodized to form the anodic oxide film
13. The anodizing process may be carried out in a sulfuric acid
solution, with the substrate 11 being an anode, and a stainless
steel board or a lead plate being a cathode. The sulfuric acid
solution may have a concentration of about 100-250 ml/L. The
electric current density through the sulfuric acid solution is
about 0.5-4.9 A/dm.sup.2. Anodizing the substrate 11 may last for
about 15-60 minutes. Then, the substrate 11 is rinsed in water and
then dried.
[0023] It is to be understood that the anodizing process can also
be carried out in a phosphoric acid solution or an oxalic acid
solution.
[0024] Referring to FIG. 4, an injection mold 20 is provided. The
injection mold 20 includes a core insert 23 and a cavity insert 21.
The core insert 23 defines several gates 231, and several first
cavities 233. The cavity insert 21 defines a second cavity 211 for
receiving the substrate 11. The anodized substrate 11 is located in
the second cavity 211, and molten resin is injected through the
gates 231 to coat the surface of the anodic oxide film 13 and fill
the nano-pores 131, and finally fill the first cavities 233 to form
the resin compositions 15, as such, the composite 100 is formed.
The molten resin may be crystalline thermoplastic synthetic resins
having high fluidity, such as PPS, PA, PET, and PBT. During the
molding process, the injection mold may be at a temperature of
about 120-170.degree. C.
[0025] Tensile strength and shear strength of the composite 100
have been tested. The tests indicate that the tensile strength of
the composite 100 is greater than 8 MPa, and the shear strength of
the composite 100 is greater than 15 MPa. Furthermore, the
composite 100 has been subjected to a temperature humidity bias
test (72 hours, 85.degree. C., relative humidity: 85%) and a
thermal shock test (48 hours, -40-85.degree. C., 4 hours/cycle, 12
cycles total), such testing did not result in decreased tensile
strength and shear strength of the composite 100.
[0026] It is believed that the exemplary embodiment and its
advantages will be understood from the foregoing description, and
it will be apparent that various changes may be made thereto
without departing from the spirit and scope of the disclosure or
sacrificing all of its advantages, the examples hereinbefore
described merely being preferred or exemplary embodiment of the
disclosure.
* * * * *