Aluminum-resin composite, insulated aluminum wire, flat cable and processes for producing the same

An insulated aluminum wire comprising:

• a metal wire made of aluminum or an aluminum alloy, and
• a thermosetting resin for coating the metal wire adhered directly to an alumina nanoporous layer which is formed directly on a surface of the metal wire and contains alumina nanoparticles of 10 nm to 50 nm in average particle diameter, wherein the alumina nanoporous layer is formed by ablating the surface of the metal with laser radiation to form nanoparticles adhered to the surface of the metal wire with nanospaces formed between the nanoparticles, wherein the thermosetting resin fills the nanospaces, and wherein a ten-point average roughness Rz of the surface of the metal is 2.1 μm to 10 μm in an interface between the metal and the thermosetting resin.

A flat cable comprising:

• conductors made of aluminum or an aluminum alloy, and
• a thermosetting resin layer adhered directly to each of the conductors from both sides of each of the conductors via an alumina nanoporous layer formed directly on a surface of each of the conductors, wherein the alumina nanoporous layer is formed by ablating the surface of each of the conductors with laser radiation to form nanoparticles of 10 nm to 50 nm in average particle diameter adhered to the surfaces of the conductors with nanospaces formed between the nanoparticles, wherein the thermosetting resin fills the nanospaces, and wherein a ten-point average roughness Rz of the surface of the metal is 2.1 μm to 10 μm in an interface between the metal and the thermosetting resin.