Metal member, composite of metal member and resin member, and production method therefor
AssigneeDenso Corporation
InventorsTakumi Nomura, Wataru Kobayashi, Kazuki Koda
Life of this patent
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Abstract
A metal member includes a metal substrate and a porous metal layer. A composite includes the metal member and a resin member. The metal substrate has one surface, is made of a metal material, and has a region formed as an uneven layer having an uneven shape with respect to the one surface. The porous metal layer has a mesh-like shape and is formed on the uneven layer. The uneven layer includes a plurality of protrusions protruding in a direction normal to the one surface.
Claims14
A metal member comprising:
- a metal substrate having one surface, made of a metal material, and having a region formed as an uneven layer having an uneven shape with respect to the one surface;
- and
- a porous metal layer having a mesh-like shape and formed on the uneven layer, wherein:
- the uneven layer includes a plurality of protrusions protruding in a direction normal to the one surface;
- the protrusions included in the uneven layer have an average height of less than 100 μm;
- and
- when a direction normal to a tangent with respect to an uneven surface as a boundary surface of the uneven layer with the porous metal layer is defined as an uneven normal direction, a thickness of the porous metal layer in the uneven normal direction is less than 1 μm.
A method for producing a metal member, the method comprising:
- providing a metal substrate having one surface and made of a metal material;
- irradiating the one surface of the metal substrate with a pulse-oscillated laser beam having an energy density of less than 300 J/cm2 with a pulse width of less than 1 μs to melt or evaporate a part or whole of the one surface;
- solidifying the melted or evaporated region of the one surface to form an uneven layer having an uneven shape from the one surface;
- and
- reattaching the evaporated metal substrate to the inside and outside of the melted or evaporated region of the one surface to form a porous metal layer having a mesh-like shape on the uneven layer.
A method for producing a composite including a metal member and a resin member, the method comprising:
- providing a metal substrate having one surface and made of a metal material;
- irradiating the one surface of the metal substrate with a pulse-oscillated laser beam having an energy density of less than 300 J/cm2 with a pulse width of less than 1 μs to melt or evaporate the one surface;
- solidifying the melted or evaporated region of the one surface to form an uneven layer having an uneven shape from the one surface;
- reattaching the evaporated metal substrate to the inside and outside of the melted or evaporated region of the one surface to form a porous metal layer having a mesh-like shape on the uneven layer, thereby producing the metal member;
- and
- causing a flowable resin material to flow onto the one surface on which the uneven layer and the porous metal layer are provided, and thereafter curing the flowable resin material to form the resin member joined to the metal member on the one surface.
Dependencies are inferred from the claim text.