# US 11,999,112 B2 · Composite structure and manufacturing method therefor

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- Number: US 11,999,112 B2
- Document ID: US11999112B2
- Status: Granted
- Kind: B2
- Application number: 17/046,515
- Filed: 2019-04-04
- Published: 2021-06-03
- Granted: 2024-06-04
- Earliest claimed: 2018-04-10
- Assignees: DIC Corporation
- Applicants: DIC Corporation
- Inventors: Kenji Nakamura; Kenta Hiwatashi; Hideaki Kikuchi
- Web page: https://patentgrep.com/patent/US11999112B2

## CPC

- B29C 45/14311: {using means for bonding the coating to the articles (B29C45/14795 takes precedence)}
- B29C 66/72321: {consisting of metals or their alloys}
- B29C 45/14: incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)}
- B29C 65/405: {characterised by the composition of the applied molten plastics (B29C65/425 takes precedence)}
- B29C 65/70: by moulding (using a particular moulding technique, see the relevant technique {, e.g. by injection B29C45/14467})
- B32B 15/08: of synthetic resin
- B32B 15/082: comprising vinyl resins; comprising acrylic resins
- B32B 15/085: comprising polyolefins
- B32B 15/088: comprising polyamides
- B32B 15/09: comprising polyesters
- B32B 15/092: comprising epoxy resins
- B32B 15/095: comprising polyurethanes
- B32B 15/098: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/18: characterised by the use of special additives
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/281: {comprising polyimides}
- B32B 27/283: {comprising polysiloxanes}
- B32B 27/285: {comprising polyethers}
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/288: {comprising polyketones}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/327: {comprising polyolefins obtained by a metallocene or single-site catalyst}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- C08L 81/02: Polythioethers; Polythioether-ethers
- B29C 2045/14868: {Pretreatment of the insert, e.g. etching, cleaning}
- B29K 2081/04: {Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof}
- B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
- B32B 2255/06: on metal layer
- B32B 2255/26: Polymeric coating
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2262/105: Ceramic fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2264/101: Glass
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/306: Resistant to heat
- B32B 2307/412: Transparent
- B32B 2307/538: Roughness
- B32B 2307/554: Wear resistance
- B32B 2307/558: Impact strength, toughness
- B32B 2307/734: Dimensional stability
- B32B 2457/08: PCBs, i.e. printed circuit boards
- B32B 2457/10: Batteries
- B32B 2457/14: Semiconductor wafers
- B32B 2457/16: Capacitors
- B32B 2509/00: Household appliances
- B32B 2605/00: Vehicles
- C08L 101/00: Compositions of unspecified macromolecular compounds
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

Provided are a composite structure that is formed by joining a metal member and a molded article of a polyarylene sulfide resin composition and is more excellent in terms of joint strength and heat cycle resistance and a producing method therefor. More specifically, provided are a composite structure formed by joining a surface-roughened metal member and a PPS member, in which a number average value of developed area ratios (Sdr) of an interface measured at five random points on a surface of the surface-roughened metal member using a confocal microscope based on ISO 25178 is 5 [%] or more, and a melt viscosity of a PPS resin is 15 to 500 [Pa·s], and a producing method therefor.

## Claims

### Claim 1

A composite structure comprising a surface-roughened metal member and a resin member made of a molded article formed by melting and molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin (A), which are joined to each other,
wherein a number average value of developed area ratios (Sdr) of an interface measured at five random points on a surface of the surface-roughened metal member using a confocal microscope based on ISO 25178 is 5% or more,
a maximum height roughness (Rz) of four random straight line points on a surface of the surface-roughened metal member using a stylus-type roughness meter based on ISO 4287 is 2 μm or more and 30 μm or less,
an average length (RSm) of four random straight line points on a surface of the surface-roughened metal member using a stylus-type roughness meter based on ISO 4287 is 10 μm or more and less than 100 μm, and
a melt viscosity of the polyarylene sulfide resin, measured using a capillary type flow tester after holding the polyarylene sulfide resin at 300° C. for six minutes with a load of 1.96×106 Pa and L/D=10 (mm)/1 (mm), is 15 Pa·s or more and 500 Pa·s or less.

### Claim 2 (depends on 1)

The composite structure according to claim 1,
wherein the polyarylene sulfide resin composition is prepared by blending 1 part by mass or more and 150 parts by mass or less of a filler (B) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 3 (depends on 1)

The composite structure according to claim 1,
wherein the polyarylene sulfide resin composition is prepared by blending 1 part by mass or more and 100 parts by mass or less of an elastomer (C) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 4

A method for producing a composite structure in which a surface-roughened metal member is joined to a resin member made of a molded article formed by melting and molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin, the method comprising:
a step (α) of melting and molding the polyarylene sulfide resin composition on a surface of a metal member to perform joining or a step (β) of joining the surface of the metal member and the molded article,
wherein a number average value (Sdr0) of developed area ratios (Sdr) of an interface measured at five random points in the surface-roughened metal member using a confocal microscope based on ISO 25178 is 5% or more,
a maximum height roughness (Rz) of four random straight line points on a surface of the surface-roughened metal member using a stylus-type roughness meter based on ISO 4287 is 2 μm or more and 30 μm or less,
an average length (RSm) of four random straight line points on a surface of the surface-roughened metal member using a stylus-type roughness meter based on ISO 4287 is 10 μm or more and less than 100 μm, and
a melt viscosity of the polyarylene sulfide resin, measured using a capillary type flow tester after holding the polyarylene sulfide resin at 300° C. for six minutes with a load of 1.96×106 Pa and L/D=10 (mm)/1 (mm), is 15 Pa·s or more and 500 Pa·s or less.

### Claim 5 (depends on 4)

The method for producing a composite structure according to claim 4, further comprising:
for preparing the surface-roughened metal member, a step of roughening the surface of the metal member,
wherein a ratio (Sdr1/Sdr0) of a number average value (Sdr1) of the developed area ratios (Sdr) of the interface at five random points on the surface of the surface-roughened metal member to the number average value (Sdr0) of the developed area ratios (Sdr) of the interface at five random points on the surface of the metal member before roughening the surface is 7 or more.

### Claim 6 (depends on 4)

The method for producing a composite structure according to claim 4,
wherein the polyarylene sulfide resin composition is prepared by blending 1 part by mass or more and 200 parts by mass or less of a filler (B) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 7 (depends on 4)

The method for producing a composite structure according to claim 4,
wherein the polyarylene sulfide resin composition is prepared by blending 0.01 parts by mass or more and 30 parts by mass or less of an elastomer (C) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 8 (depends on 2)

The composite structure according to claim 2,
wherein the polyarylene sulfide resin composition is prepared by blending 1 part by mass or more and 100 parts by mass or less of an elastomer (C) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 9 (depends on 7)

The method for producing a composite structure according to claim 7,
wherein the polyarylene sulfide resin composition is prepared by blending 1 part by mass or more and 200 parts by mass or less of a filler (B) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 10 (depends on 5)

The method for producing a composite structure according to claim 5,
wherein the polyarylene sulfide resin composition is prepared by blending 0.01 parts by mass or more and 30 parts by mass or less of an elastomer (C) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 11 (depends on 6)

The method for producing a composite structure according to claim 6,
wherein the polyarylene sulfide resin composition is prepared by blending 0.01 parts by mass or more and 30 parts by mass or less of an elastomer (C) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 12 (depends on 9)

The method for producing a composite structure according to claim 9,
wherein the polyarylene sulfide resin composition is prepared by blending 0.01 parts by mass or more and 30 parts by mass or less of an elastomer (C) with 100 parts by mass of the polyarylene sulfide resin (A), followed by melting and kneading.

### Claim 13 (depends on 1)

The composite structure according to claim 1,
wherein the maximum height roughness (Rz) of four random straight line points on the surface of the surface-roughened metal member using a stylus-type roughness meter based on ISO 4287 is 5 μm or more and 22 μm or less.

### Claim 14 (depends on 4)

The method for producing a composite structure according to claim 4,
wherein the maximum height roughness (Rz) of four random straight line points on the surface of the surface-roughened metal member using a stylus-type roughness meter based on ISO 4287 is 5 μm or more and 22 μm or less.