Composite article of aluminum alloy with resin and method for production thereof

Abstract

An aluminum alloy material is prepared that has surface configuration of threefold irregularities such that rough surface having surface roughness of 10 to 100 μm period is observed with an electron microscope in a magnification of 1000 times, surface having fine irregularities of 1 to 5 μm period based on crystal grain boundary is observed with an electron microscope in a magnification of 10000 times and surface having ultrafine irregularities of 30 to 100 nm period is confirmed with an electron microscope in a magnification of 100000 times. Aluminum alloy material is integrally joined with a resin composition consisting of a total resin part containing polyphenylene sulfide resin by 70 mass % or more of the resin part, modified polyolefin resin by 30 mass % or less of the resin part and a resin of third component having ability for promoting compatibility of polyphenylene sulfide resin and modified polyolefin resin.

1 . A composite of aluminum alloy and resin, comprising:
 an aluminum alloy having surface configuration of threefold irregularities such that a rough surface having surface roughness of 10 to 100 μm period is observed with an electron microscope in a magnification of 1000 times, a surface having fine irregularities of 1 to 5 μm period based on crystal grain boundary is observed with an electron microscope in a magnification of 10000 times and a surface having ultrafine irregularities of 30 to 100 nm period is confirmed with an electron microscope in a magnification of 100000 times, and   a resin composition consisting of a total resin part and a filler part, the total resin part containing a polyphenylene sulfide resin as a main component by 70 mass % or more of a resin part, and a modified polyolefin resin as an auxiliary component by 30 mass % or less of the resin part, and further containing a resin of third component having ability for promoting compatibility of the polyphenylene sulfide resin and the modified polyolefin resin, and the filler part of reinforcing fiber being 15 to 30 mass % of an entire resin composition;   wherein the aluminum alloy and the resin composition are directly and integrally joined, a joining strength between two parts of an integrated entity of the aluminum alloy and the resin composition as a molded entity is a high joining strength equal to or greater than 30 MPa for both of shear joining strength and tensile joining strength.   
     
     
         2 . A composite of aluminum alloy and resin according to  claim 1 ,
 wherein the surface having ultrafine irregularities is one having porous structure formed by an anodization method.   
     
     
         3 . A composite of aluminum alloy and resin according to  claim 1 ,
 wherein amine molecules are chemically adsorbed onto the surface having ultrafine irregularities.   
     
     
         4 . A method for manufacturing the composite of aluminum alloy and resin according to  claim 1 ,
 wherein the aluminum alloy and the resin composition that are integrally joined is performed in a manner such that:   amine molecules are chemically adsorbed onto the surface having ultrafine irregularities formed by chemical treatment, and   the aluminum alloy is inserted into a metallic mold for injection molding, after which the resin composition is injected into the metallic mold.   
     
     
         5 . A composite of aluminum alloy and resin according to  claim 2 ,
 wherein amine molecules are chemically adsorbed onto the surface having ultrafine irregularities.   
     
     
         6 . A method for manufacturing the composite of aluminum alloy and resin according to  claim 2 ,
 wherein the aluminum alloy and the resin composition that are integrally joined is performed in a manner such that:   amine molecules are chemically adsorbed onto the surface having ultrafine irregularities formed by chemical treatment, and   the aluminum alloy is inserted into a metallic mold for injection molding, after which the resin composition is injected into the metallic mold.