Composite material of aluminum alloy and resin and production method therefor

Abstract

The present invention allows both the merits of a metallic housing and those of a synthetic resin structure to be exhibited in electronic devices, domestic electric devices, etc., and achieves high productivity and mass production capability as well as enables a desired configuration and structure to be designed freely. The present invention is useful for achieving a reduction in weight and for attaining increased strength in not only electronic devices and domestic electric devices but also various parts and structures. As a pretreatment, a rib ( 3 ) is dipped in an aqueous solution of at least one selected from the group consisting of ammonia, hydrazine, a hydrazine derivative, and a water-soluble amine compound. A metal frame ( 2 ) is inserted into an injection mold for forming ribs ( 3 ) by injection molding. A thermoplastic resin composition is injected to the surface of the metal frame ( 2 ) by injection molding to form ribs ( 3 ). In the housing of a casing cover ( 1 ) thus formed, the metal frame ( 2 ) and the ribs ( 3 ) made of the thermoplastic resin composition are integrally bonded together. Thus, the housing can make use of the characteristic features of the metal in terms of strength and design of external appearance. Moreover, a complicated configuration and structure can be formed in the housing.

What is claimed is:  
     
         1 . An aluminum alloy-and-resin composite comprising: 
 a shaped aluminum alloy material that has been subjected to a contact process in which it is brought into contact with at least one compound selected from the group consisting of ammonia, hydrazine, a hydrazine derivative, and a water-soluble amine compound; and    a resin material integrally bonded to a surface of said shaped aluminum alloy material, said resin material being at least one selected from the group consisting of a polyalkylene terephthalate, a copolymer consisting essentially of said polyalkylene terephthalate, and a thermoplastic resin composition containing said polyalkylene terephthalate as a component.    
     
     
         2 . An aluminum alloy-and-resin composite according to  claim 1 , wherein said contact process brings said shaped aluminum alloy material into contact with an aqueous solution having said compound dissolved therein.  
     
     
         3 . An aluminum alloy-and-resin composite according to  claim 1 , wherein said polyalkylene terephthalate is polybutylene terephthalate.  
     
     
         4 . An aluminum alloy-and-resin composite according to any one of  claims 1  to  3 , wherein said shaped aluminum alloy material has been subjected to a neutralization treatment in which it is dipped in a basic aqueous solution and then dipped in an acid aqueous solution before said contact process.  
     
     
         5 . An aluminum alloy-and-resin composite according to any one of  claims 1  to  4 , wherein said shaped aluminum alloy material is dipped in an aqueous solution of a water-soluble reducing agent before said contact process.  
     
     
         6 . An aluminum alloy-and-resin composite according to  claim 3 , wherein said polybutylene terephthalate is at least one selected from the group consisting of a polymer consisting singly of polybutylene terephthalate, a polymer compound of polybutylene terephthalate and polycarbonate, a polymer compound of polybutylene terephthalate and acrylonitrile-butadiene-styrene resin, a polymer compound of polybutylene terephthalate and polyethylene terephthalate, and a polymer compound of polybutylene terephthalate and polystyrene.  
     
     
         7 . An aluminum alloy-and-resin composite according to  claim 4 , wherein said contact process brings said shaped aluminum alloy material into contact with a gas produced by gasifying said compound.  
     
     
         8 . An aluminum alloy-and-resin composite according to  claim 7 , wherein said polymer has a filler added thereto to improve physical properties.  
     
     
         9 . An aluminum alloy-and-resin composite according to  claim 7 , wherein said polymer has a high-strength fiber added thereto to increase mechanical strength.  
     
     
         10 . An aluminum alloy-and-resin composite according to  claim 8 , wherein said filler comprises at least one selected from the group consisting of carbon black, calcium carbonate, calcium silicate, magnesium carbonate, silica, talc, clay, lignin, asbestos, mica, silica powder, and glass globules.  
     
     
         11 . An aluminum alloy-and-resin composite according to  claim 9 , wherein said high-strength fiber comprises at least one selected from the group consisting of glass fiber, carbon fiber, and aramid fiber.  
     
     
         12 . A method of producing a composite of an aluminum alloy and a thermoplastic resin composition, said method comprising: 
 a processing step of forming said aluminum alloy into a shaped aluminum alloy material by machining;    a contact step of bringing said shaped aluminum alloy material into contact with at least one compound selected from the group consisting of ammonia, hydrazine, a hydrazine derivative, and a water-soluble amine compound; and    a forming step of inserting said shaped aluminum alloy material, which has been contact-treated in said contact step, into a mold for a forming process, and integrating a resin material to a surface of said shaped aluminum alloy material under pressure and heating, said resin material being at least one selected from the group consisting of a polyalkylene terephthalate, a copolymer consisting essentially of said polyalkylene terephthalate, and a thermoplastic resin composition containing said polyalkylene terephthalate as a component.    
     
     
         13 . A method of producing a composite of an aluminum alloy and a resin according to  claim 12 , wherein said contact step brings said shaped aluminum alloy material into contact with an aqueous solution having said compound dissolved therein.  
     
     
         14 . A method of producing a composite of an aluminum alloy and a resin according to  claim 12 , wherein said forming step is carried out by injection molding.  
     
     
         15 . A method of producing a composite of an aluminum alloy and a resin according to  claim 12 , wherein said polyalkylene terephthalate is polybutylene terephthalate.  
     
     
         16 . A method of producing a composite of an aluminum alloy and a resin according to any one of  claims 12  to  15 , said method having a step between said processing step and said contact step, said step comprising: 
 a first dipping step of dipping said shaped aluminum alloy material in a basic aqueous solution; and  
 a second dipping step of dipping said shaped aluminum alloy material, which has been dip-treated in said first dipping step, in an acid aqueous solution to neutralize said shaped aluminum alloy material.  
 
     
     
         17 . A method of producing a composite of an aluminum alloy and a resin according to any one of  claims 12  to  15 , said method having between said processing step and said contact step a step of dipping said shaped aluminum alloy material in an aqueous solution of a water-soluble reducing agent.  
     
     
         18 . A method of producing a composite of an aluminum alloy and a resin according to  claim 15 , wherein said polybutylene terephthalate is at least one selected from the group consisting of a polymer consisting singly of polybutylene terephthalate, a polymer compound of polybutylene terephthalate and polycarbonate, a polymer compound of polybutylene terephthalate and acrylonitrile-butadiene-styrene resin, a polymer compound of polybutylene terephthalate and polyethylene terephthalate, and a polymer compound of polybutylene terephthalate and polystyrene.  
     
     
         19 . A method of producing a composite of an aluminum alloy and a resin according to  claim 16 , wherein said basic aqueous solution is an aqueous solution of an alkali metal hydroxide.  
     
     
         20 . A method of producing a composite of an aluminum alloy and a resin according to  claim 17 , wherein said water-soluble reducing agent is at least one selected from the group consisting of an alkali-metal sulfite, an alkali-metal hydrogensulfite, hydrazine, an alkali-metal borohydride, and an alkali-metal aluminum hydride.  
     
     
         21 . A method of producing a composite of an aluminum alloy and a resin according to  claim 17  or  18 , wherein said contact step brings said shaped aluminum alloy material into contact with a gas produced by gasifying said compound.  
     
     
         22 . A method of producing a composite of an aluminum alloy and a resin according to  claim 18 , wherein said polymer has a high-strength fiber added thereto to increase mechanical strength.  
     
     
         23 . A method of producing a composite of an aluminum alloy and a resin according to  claim 22 , wherein said high-strength fiber comprises at least one selected from the group consisting of glass fiber, carbon fiber, and aramid fiber.  
     
     
         24 . A method of producing a composite of an aluminum alloy and a resin according to  claim 19 , wherein said polymer has a filler added thereto to improve physical properties.  
     
     
         25 . A method of producing a composite of an aluminum alloy and a resin according to  claim 24 , wherein said filler comprises at least one selected from the group consisting of carbon black, calcium carbonate, calcium silicate, magnesium carbonate, silica, talc, clay, lignin, asbestos, mica, silica powder, and glass globules.