經電化學處理鋁合金1050與射出成型塑料接合效果之探討

Abstract

嵌入式射出成型是一種在塑料射出過程中將金屬與塑膠接合的技術，在許多電子產品中廣泛被運用，但是傳統嵌入式射出成型為了增加接合強度必須對金屬做卡溝設計或是使用黏著劑，不過現在已有許多新的金屬塑膠接合技術被開發，它們不需要卡溝設計和黏著劑就能直接在射出成型時將塑料與金屬接合並且擁有高強度的黏合力，這些技術有助簡化製造程序和降低成本。 許多接合技術皆使用化學蝕刻讓金屬表面粗化，文獻指出讓金屬和塑料能夠接合的原因，表面的粗糙度和多孔特性有助於金屬和塑料利用物理性的固錨力結合。 本研究則使用兩種電化學加工方法，微弧氧化和陽極氧化鋁改質鋁合金1050的表面，於表面生成氧化薄膜，探討兩種不同金屬表面樣貌的薄膜對塑料接合強度的影響。 本實驗結果顯示微弧氧化形成的氧化薄膜無法提供強大的固錨結合力，但是微弧氧化薄膜表面所提供的接合力能把較脆弱的薄膜拔起，而陽極氧化鋁能夠使塑料接合在薄膜上，但是抗剪強度的測量並沒有明顯趨勢，其值在6-10MPa間。

Insert molding is a way to combine plastic in viscous fluid state with metal. The technique is wildly used in electronic products. In order to increase the bonding between plastic and metal it must spends more to design snap fittings or use glue. In this study a new way to enhance the adhesion between plastic and metal was proposed. It could directly inject plastic on metal with high bonding joint without using any epoxy or any snap fittings. The new technique can reduce many manufacturing processes and cost. Most of plastic/metal adhesion techniques use chemical etching modify metal’s surface. There are many researches indicating that roughness and porosity may benefit to make resins interlock on metal’s surface. So this study is ready to use two electrochemical processes, micro-arc oxidation and anodic aluminum oxidation to treat aluminum 1050 and produce aluminum oxide layer. Then the surface morphology effects out the adhesion joint between resins and aluminum were discussed. The result show that Micro Arc Oxidation treated aluminum surface cannot provide enough interlocking joint to make resins adhere to surface firmly. And AAO treatment could make resins adhered but the bonding strength still not satisfactory because of air traped in micro structure. The bonding strength was about 10 MPa in maximum.