COMPOSITE ARTICLE OF MAGNESIUM MATERIAL AND RESIN COMPONENT, AND METHOD FOR PRODUCING SAID COMPOSITE ARTICLE
To be able to efficiently produce a resin component on a magnesium material. [Solution] A composite article is produced by forming an anodic oxide film on one surface of a magnesium material as a consequence of immersing the magnesium material into an electrolyte solution and applying a voltage, and by joining a resin component to the magnesium material by using the anodic oxide film. The electrolyte solution is formed by dissolving sodium dihydrogen phosphate and sodium hydroxide in pure water. The weight mixture ratio (R1) of sodium dihydrogen phosphate and sodium hydroxide is 1:2≦R1<2:1, and the voltage is between 20 and 50 V.
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1. Field of the Invention
The present invention relates to a composite article of magnesium material, and method for producing said composite article.
2. Description of Related Art
Using a mould for insert forming is a well-known method to join a resin component with metallic material, in detail a metallic component made of iron or steel is inserted into the cavity of the mould, and under this state, molten resin is injected into the cavity so that a portion of the metallic component is embedded inside the resin component of an expected shape.
In addition, to join aluminum material with a resin component, a well-known method is to form an anodic oxide film on the surface of the aluminum material with multiple pores with diameters of over 25 nm, and cause part of the resin to bite into the pores of the anodic oxide film through a method like injection forming.
PREVIOUS LITERATURESPatent Literature 1-Descriptions of International Publication No. 2004/055248
SUMMARY OF THE INVENTIONIn recent years, to obtain components with light weight and high strength, magnesium material is frequently used to replace aluminum material, and there is a need to join magnesium material with a resin component. In view of this need, the objective of the present invention is to provide a method to efficiently produce a composite article with magnesium material and resin component.
To overcome the afore-mentioned problem, the present invention provides a method to produce a composite article with magnesium material and resin component, with its characteristics residing in the inclusion of: a process to immerse the magnesium material into an electrolyte solution formed by dissolving sodium dihydrogen phosphate and sodium hydroxide in pure water; a process to apply a voltage upon said magnesium material immersed with said electrolyte solution, so as to form an anodic oxide film on the surface of said magnesium material; and a process to fill part of the resin component into the multiple pores on said anodic oxide film so as to join said magnesium material with said resin component.
Furthermore, in the above production method, the weight mixture ratio R1 of said sodium dihydrogen phosphate and said sodium hydroxide is 1:2≦R1<2:1.
Furthermore, in the above production method, the voltage applied on said magnesium material is 10V˜50V.
Furthermore, in the above production method, the weight proportion of said sodium dihydrogen phosphate and said sodium hydroxide is 1:1.
Meanwhile, the present invention provides a composite article, which is a finished product produced by means of the above production method.
Based on the method disclosed in the present invention to generate an anodic oxide film on the magnesium material through an electrolyte solution formed by mixing sodium hydroxide and sodium dihydrogen phosphate, the resin component can be stably joined.
The sectional view in
The method to produce a composite article with magnesium material and resin component is briefly described based on the process flow chart in
Firstly, take Step S101 to die-press the magnesium material 2 to form the required shape. Then, take Step S102 to generate a joining film on the magnesium material 2, and consequently form a porous anodic oxide film 3.
Furthermore, take Step S103 to join the resin component 4 on the area formed with an anodic oxide film 3. As shown in
Furthermore, take Step S104 to conduct an after-treatment of the composite article 1. The after-treatment is to coat the other surface 28 of the magnesium material 2. Alternatively, it is also fine to finish the processing without applying Step S104.
Below is a detailed description of the process to form a joining film in Step S102.
Firstly, degreasing treatment and neutralizing treatment of the magnesium material 2 are carried out as needed. Then, put the magnesium material 2 into an electrolytic bath. The electrolytic bath contains an electrolyte solution formed by dissolving a strong alkaline substance and a weak acid substance in pure water. The strong alkaline substance can be, for example, sodium hydroxide. The weak acid substance is sodium phosphate, and more specifically, sodium dihydrogen phosphate (NaH2PO4). The weights of sodium hydroxide and sodium dihydrogen phosphate dissolved in 40L of pure water respectively range from 1 kg to 3 kg. Furthermore, the temperature of the electrolyte solution is adjusted to be 30° C.˜40° C. The magnesium material 2 is used as the anode, while the cathode is something like a stainless steel plate. Moreover, within a voltage range of 10V˜50V, electrical decomposition is carried out through a direct current method for 3˜10 minutes, for example.
In this way, as shown in the sectional view in
Furthermore, the process in Step S103 to join the resin component 4 and the magnesium material 2 is described below.
The resin 24 can be any resin like PP (polypropylene), PE (polyethylene), PBT (polybutylene terephthalate), PPS (polyphenylene sulfide) or silicon rubber. In addition, considering the difference of linear expansion between magnesium material 2 and resin 24, the resin material of the resin component produced through the afore-mentioned injection forming can provide a flexibility to absorb the difference of linear expansion, and the resin has an excellent elasticity up to 10000 Mpa. There are also options of resins with-good resistance to hot water and drug. Suitable resins 24 include olefin resins like PBT, PE or PP.
To form the resin component 4, open the mould 21, fit the magnesium material 2 inside the space 22. Face the anodic oxide film 3 of the magnesium material 2 upward, i.e., face the anodic oxide film 3 toward the gate 25. After closing the mould 21, press and fill the molten resin 24 into the cavity, and meanwhile fill the resin into the multiple pores of the anodic oxide film 3.
After this, open the mould, and a composite article 1 as shown in
In the composite article 1 produced through the above method, the joining strength between the magnesium material 2 and the resin component 4 is very good. The compressive strength measured by a stress testing machine is higher than 20N. In addition, in the process to join the resin component 4 and the magnesium material, heat pressing or other methods are all applicable.
As described above, the embodiments of the present invention use an electrolyte solution formed by mixing sodium hydroxide and sodium dihydrogen phosphate to generate an anodic oxide film 3 on the magnesium material 2, so that it can join with the resin component 4.
Below are detailed descriptions of the present invention based on the embodiments:
In the embodiment disclosed in
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From the above results, such as the embodiment shown in
Furthermore, as shown in the embodiment of
In contrast, as shown in the embodiments in
Furthermore, under a condition that the weight of sodium dihydrogen phosphate dissolved in pure water is not too much more than that of sodium hydroxide, a stable joining strength can be obtained. The weight ratio R1 between sodium dihydrogen phosphate and sodium hydroxide is 1:2≦R1<2:1. However, an ideal weight ratio R1 is 1:1. Under this condition, the voltage applied on the magnesium material 2 is 10V or higher, ideally 10V˜50V. Based on this, it is possible to produce a composite article 1 with stable joint between the resin component 4 and the magnesium material 2 having sufficient joining strength.
In addition, the composite article in each embodiment can be applied in the components of electric or electronic appliances such as personal computer or mobile phone, or the interior and exterior fittings of building materials or buildings, or the interior and exterior fittings of ships, airplanes, railway cars, and automobiles, or decorative items like license plates, or any other composite article with magnesium material and resin component of any shape or any size.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may he embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and ail changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims
1. A method for producing a composite article of magnesium material and resin component, comprising the steps of:
- immersing a magnesium material into an electrolyte solution formed by dissolving sodium dihydrogen phosphate and sodium hydroxide in pure water;
- applying a voltage upon said magnesium material immersed with said electrolyte solution, so as to form an anodic oxide film on the surface of said magnesium material; and
- filling part of the resin component into the multiple pores on said anodic oxide film so as to join said magnesium material with said resin component.
2. The method defined in claim 1, wherein the weight mixture ratio R1 of said sodium dihydrogen phosphate and said sodium hydroxide is 1:2≦R1<2:1.
3. The method defined in claim 1, wherein the voltage applied on said magnesium material is 10V˜50V.
4. The method defined in claim 1, wherein the weight proportion of said sodium dihydrogen phosphate and said sodium hydroxide is 1:1.
5. A composite article of magnesium material and resin component comprising:
- said composite article made by the following steps:
- immersing a magnesium material into an electrolyte solution formed by dissolving sodium dihydrogen phosphate and sodium hydroxide in pure water;
- applying a voltage upon said magnesium material immersed with said electrolyte solution, so as to form an anodic oxide film on the surface of said magnesium material; and
- filling part of the resin component into the multiple pores on said anodic oxide film so as to join said magnesium material with said resin component.
6. The composite article of claim 5, wherein the weight mixture ratio R1 of said sodium dihydrogen phosphate and said sodium hydroxide is 1:2≦R1<2:1.
7. The composite article of claim 5, wherein the voltage applied on said magnesium material is 10V˜50V.
8. The composite article of claim 5, wherein the weight proportion of said sodium dihydrogen phosphate and said sodium hydroxide is 1:1.
Type: Application
Filed: Jul 25, 2013
Publication Date: Jun 18, 2015
Applicant: DONG GUAN QINDE METAL PRODUCTS CO., LTD. (Dongguan, Guangdong)
Inventors: Tsuyoshi Tanaka (Dongguan), Yasuhiro Watanabe (Dongguan), Toshiyuki Nabekura (Dongguan)
Application Number: 14/416,277